Molded surface fastener manufacturing method

ABSTRACT

In this molded surface fastener, plural engaging elements having a stem portion and an engaging head portion formed integrally on the stem portion are standing on the base portion, at least one pawl portion having a pawl width dimension narrower than a width dimension at a boundary between the stem portion and the engaging head portion is protruded on an outer peripheral edge part of the engaging head portion, and a back surface of pawl of the pawl portion is formed at different angles with respect to a back surface of head portion of the engaging head portion. Such a molded surface fastener of the present invention has a substantial engaging force with respect to a female surface fastener and can make a texture of its surface comfortable.

This application is a divisional of U.S. Ser. No. 16/061,979, which isincorporated herein in its entirety by reference.

TECHNICAL FIELD

The invention relates to a molded surface fastener in which a pluralityof male engaging elements are standing on an upper surface of a flatplate-shaped base portion, a manufacturing method of the molded surfacefastener and a molding apparatus used for manufacturing the moldedsurface fastener.

BACKGROUND ART

Conventionally, surface fastener products used by combining a femalesurface fastener having a plurality of loops and a male molded surfacefastener capable of engaging and disengaging with the female surfacefastener as a pair are known. Generally, a male molded surface fasteneris formed such that a plurality of male engaging elements having a hookor a mushroom shape and the like are standing on an upper surface of aflat-plate shaped base portion.

Presently, surface fastener products having such a male molded surfacefastener are widely used in a various kinds of goods. For example, it isoften used for goods to be put on and taken off from a body such as adisposable diaper, a diaper cover for babies and infants, a supporterprotecting joints of arms and legs, a corset for waist (belt forbackache) and gloves.

Many kinds of molded surface fasteners used for a disposable diaper havebeen developed until now and they are disclosed in Japanese patentpublication No. 2013-529974A (Patent Document 1) and U.S. patentpublication No. 2013/0067702A (Patent Document 2), for example.

For example, as shown in FIGS. 44 and 45, a surface fastener 100described in Patent Document 1 is formed such that a plurality of maleengaging elements 102 are standing on a flat plate-shaped base portion101. Each engaging element 102 has a frustum-shaped stem portion 103 andan engaging head portion 104 formed integrally on the stem portion 103.The engaging head portion 104 is formed so as to bulge from the stemportion 103 with a substantially equal volume in all directions.

In Patent Document 1, regarding at least some of the engaging elements102, a bulging part 104 a extending in only one direction of X directionor Y direction in the engaging head portion 104 is directed downwardtoward the base portion 101. According to Patent Document 1, the moldedsurface fastener 100 having engaging elements 102 as shown in FIGS. 44and 45 can have a strong peeling strength when it is engaged with asurface fastener 100 having loop-shaped female engaging elements 102.

In Patent Document 2, as a molded surface fastener whose engaging anddisengaging property is strengthened, a molded surface fastener having aplurality of male engaging elements 112, for example, as shown in FIGS.46 and 47 is described. An engaging element 112 in Patent Document 2 hasa stem portion 113 standing on a base portion 111 and an engaging headportion 114 formed integrally on the stem portion 113. A plurality ofteeth 115 are provided on an outer peripheral edge part of the engaginghead portion 114 so as to be a rotational symmetry about a center point.Further, the molded surface fastener in Patent Document 2 has anengaging element 112 a in which the engaging head portion 114 is formedapproximately parallel to the base portion 111 and an engaging element112 b in which the engaging head portion 114 is formed so as to rollback upward toward the outer peripheral edge.

In Patent Document 2, in a case of manufacturing the molded surfacefastener, a method that a molten synthetic resin material is extrudedbetween a molding roller and a pressure roller is adopted. In this case,a plurality of molding cavities having a shape corresponding to theengaging element 112 of the molded surface fastener are formed on anouter peripheral surface of the molding roller.

The synthetic resin material is extruded between such a molding rollerand a pressure roller, thereby the base portion 111 is molded in a gapbetween the molding roller and the pressure roller. Further, thesynthetic resin material is pushed into molding cavities of the moldingroller by the pressure roller, thereby the engaging element 112 ismolded integrally to the base portion 111. Then, after the syntheticresin material is cured while rotated together with the molding roller,the cured synthetic resin is picked up from the molding cavities of themolding roller and is peeled off from the molding roller. Thus themolded surface fastener in Patent Document 2 is manufactured.

Documents other than the above-mentioned Patent Documents 1 and 2,Japanese Patent Publication No. 2002-519078A (Patent Document 3) andJapanese Patent Publication No. 2002-262908A (Patent Document 4), forexample, disclose a manufacturing method or a manufacturing apparatus ofa surface fastener having a plurality of male engaging elements.

For example, in the manufacturing method described in Patent Document 3,firstly, a primary molding step for molding a primary molded body havinga flat plate-shaped base portion, a stem portion standing on the baseportion and a primary head portion formed integrally on the stem portionis conducted. Thereafter, a secondary molding step for molding theprimary head portion so as to be an engaging head portion by extendingthe primary head portion flatly in a radial direction by making theprimary molded body pass through a calender and pressing the primaryhead portion of the primary molded body is conducted.

In this case, a molding apparatus for the above-mentioned primarymolding has a molding cylinder to be rotated, a press cylinder disposedopposing to the molding cylinder and setting a predetermined intervaland an extrusion head providing a molten thermoplastic resin between themolding cylinder and the press cylinder. Further, the molding cylinderin Patent Document 3 has a cylinder-shaped outside screen and acylinder-shaped inside screen contacting with an inner peripheralsurface of the outside screen.

A plurality of column-shaped hollows molding the stem portion are formedon the outside screen of the molding cylinder. A plurality ofcolumn-shaped hollows molding the primary head portion are formed on theinside screen. Each hollow on the outside screen and each hollow on theinside screen are disposed aligning at a position corresponding to eachother.

By using the molding apparatus having such a molding cylinder, thethermoplastic resin is provided from the extrusion head between themolding cylinder and the press cylinder while the molding cylinder andthe press cylinder are rotated, thereby the primary molded body in whicha plurality of engaging elements which has a stem portion and a primaryhead portion in which a depression is formed are standing on the baseportion is molded.

Thereafter, the obtained primary molded body is passed through thecalender and each primary head portion is made to be thin, thereby themolded surface fastener in Patent Document 3 in which a plurality ofmushroom-shaped engaging elements are standing on the base portion ismanufactured. The molded surface fastener manufactured in PatentDocument 3 has a characteristic that a concave portion is formed on acenter part of an upper surface in the engaging head portion of eachengaging element.

On the other hand, a manufacturing apparatus of the molded surfacefastener described in Patent Document 4 has a continuously-injectingapparatus molding an auxiliary molded body having a plurality ofauxiliary molded element on a base portion and a heat press apparatushaving a pair of upper and lower rollers disposed on a downstream sideof the continuously-injecting apparatus and molding an engaging elementby melting and deforming the auxiliary molded element.

The continuously-injecting apparatus has a cylindrical drum in whichcavities for molding are formed on a peripheral surface part androtating in one direction, an extrusion nozzle extruding the moltenresin continuously toward the peripheral surface of the cylindrical drumand a take-up roller peeling off the auxiliary molded body molded on theperipheral surface of the cylindrical drum from the cylindrical drum. Inthis case, the cylindrical drum is a hollow-drum shape having a watercooling jacket which is a means of cooling inside and a peripheralsurface has a function as a part of molded surface of the molded surfacefastener.

Generally, the cylindrical drum is formed as column-shaped by laminatinga plurality of ring-shaped (donut-shaped) plates having a necessarythickness in a rotating axis direction of the cylindrical drum. Further,predetermined cavities for molding are formed on a peripheral edge partof the predetermined ring-shaped plate at a predetermined pitch in acircumferential direction corresponding to a position of the plate by anelectrical discharge machining or a laser processing.

By using the continuously-injecting apparatus, the molten resin materialis extruded continuously from the extrusion nozzle toward the peripheralsurface of the cylindrical drum, thereby the auxiliary molded body ismolded continuously. Further, the auxiliary molded body is peeled offfrom the cylindrical drum via the take-up roller and conveyed to theheat press apparatus.

Thereafter, the auxiliary molded body conveyed to the heat pressapparatus is introduced between a lower roll and an upper part heatpressing roll, thereby an auxiliary molded element of the auxiliarymolded body is pressed from an upper side, then a flat and thinplate-shaped engaging head portion is molded. Thus, the molded surfacefastener in Patent Document 4 in which a plurality of engaging elementshaving a cross-shaped post portion and a characteristic, approximatelyrectangular and thin plate-shaped engaging head portion are standing onthe base portion is manufactured.

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: Japanese Patent Publication No. 2013-529974A

Patent Document 2: U.S. Patent Publication No. 2013/0067702A

Patent Document 3: Japanese Patent Publication No. 2002-519078A

Patent Document 4: Japanese Patent Publication No. 2002-262908A

SUMMARY OF INVENTION Problem to be Solved by the Invention

Normally, regarding the molded surface fastener used for goods which areput on a body such as the above-mentioned disposable diaper or diapercover, it is required that an engaging strength (peeling strength) isenhanced so as an engaging and disengaging operation of a male surfacefastener and a female surface fastener to be easy and both surfacefasteners not to be separated easily even when a wearer moves in a stateof engaging both surface fasteners. Further, depending on goods to beused, the molded surface fastener often contacts directly to a skin.Therefore, it is also desired to make a texture of the top surface sidein which the male engaging elements of the molded surface fastener aredisposed smooth so as to obtain soft tactile.

However, for example, in the molded surface fastener 100 having maleengaging elements 102 in Patent Document 1 (see FIGS. 44 and 45), theengaging strength in an orthogonal direction to a bulging part 104 a ofthe engaging head portion 104 is weak in comparison to a direction inwhich the bulging part 104 a is directed downward.

In the molded surface fastener having male engaging elements 112 inPatent Document 2 (see FIGS. 46 and 47), since large concaves andconvexes are formed in an outer peripheral edge part of the engaginghead portion 114, certainly the engaging strength is expected to beenhanced, but the tactile can be significantly worsen. In addition,since a concave part is formed on an upper surface of each engaging headportion of the molded surface fastener having the male engaging elementsin Patent Document 3, the texture of the molded surface fastener seemsto be deteriorated, and moreover, the substantial engaging strengthseems to be hard to be obtained.

In a case that the molded surface fastener is manufactured by using themolding apparatus described in Patent Document 4, since the cylindricaldrum is formed by laminating a plurality of ring-shaped plates asmentioned above, small burrs may occur in the primary molded body at aboundary part of the adjacent ring-shaped plates. Moreover, since aposition of the laminated ring-shaped plates are easy to misalign alittle in the circumferential direction of the cylindrical drum, thereis a possibility that a shape of the engaging element is affected.Therefore, the molding apparatus in Patent Document 4 becomes less usedin manufacturing the molded surface fasteners to which a comfortabletexture is required or the small size molded surface fasteners.

The present invention was made in light of the above-mentionedconventional problems. Its specific objective is to provide a moldedsurface fastener which has a substantial engaging strength (peelingstrength) with respect to a female surface fastener and from which acomfortable texture can be stably obtained, and further provide amanufacturing method by which such a molded surface fastener can bestably manufactured and a molding apparatus used for manufacturing themolded surface fastener.

Means for Solving the Problem

To achieve the above objective, the molded surface fastener provided bythe present invention is, as a basic structure, the one made ofsynthetic resin in which a plurality of male engaging elements arestanding on an upper surface of a flat plate-shaped base portion andeach engaging element has a stem portion standing on the base portionand an engaging head portion bulging from an upper end of the stemportion toward an outside and formed integrally on the stem portion, inwhich in at least a part of the engaging elements, at least one pawlportion having a pawl width dimension narrower than a width dimension ata boundary between the stem portion and the engaging head portion isprotruded on an outer peripheral edge part of the engaging head portionand a back surface of pawl disposed opposing to the base portion of thepawl portion is formed at different angles with respect to a backsurface of head portion extending from the boundary of the engaging headportion to an outside, as a most principal configuration.

In particular, it is preferable that the pawl portion of the moldedsurface fastener of the present invention is formed to slope or curvedownward toward the base portion.

In the molded surface fastener of the present invention, it ispreferable that a plurality of the pawl portions are provided withrespect to one engaging head portion. In this case, it is preferablethat a plurality of the pawl portions are disposed on the engaging headportion regularly. Further, a plurality of the pawl portions may bedisposed on the engaging head portion irregularly.

Moreover, in the present invention, it is preferable that a plurality ofthe pawl portions are formed at different angles respectively. Inaddition, it is preferable that a plurality of the pawl portions areformed with different sizes respectively.

In the molded surface fastener in the present invention, it ispreferable that an upper surface of pawl and the back surface of pawl ofthe pawl portion are formed to be a sloped surface or a curved surfacedeclining toward a tip end.

It is preferable that the engaging head portion has a shape appearing aconfiguration similar to a cross section at the boundary in a plan view.It is preferable that the engaging head portion has a shape appearing acircle in a plan view.

In the molded surface fastener in the present invention, it ispreferable that a base end part of the pawl portion has a pawl widthdimension narrower than one third size of a width dimension of theboundary.

Further, it is preferable that a height dimension from the upper surfaceof the base portion in the engaging element is set to be 0.05 mm or moreand 1.5 mm or less, a width dimension at the boundary is set to be 0.1mm or more and 0.5 mm or less, a bulging length from the boundary in theengaging head portion is set to be 0.01 mm or more and 0.2 mm or less,and a pawl width dimension in the base end part of the pawl portion isset to be 0.01 mm or more and 0.1 mm or less.

Next, a manufacturing method of the molded surface fastener provided bythe present invention is to manufacture a molded surface fastener madeof synthetic resin in which a plurality of male engaging elements arestanding on an upper surface of a flat plate-shaped base portion andeach engaging element has a stem portion standing on the base portionand an engaging head portion bulging from an upper end of the stemportion toward an outside and formed integrally on the stem portion,including a primary molding step for molding a primary molded bodyhaving the base portion and a plurality of provisional elements standingon the base portion and a secondary molding step for molding the moldedsurface fastener by heating the provisional elements of the primarymolded body and compressing the provisional elements from an upper side,and further including molding a primary stem portion erected from thebase portion, a bulging portion bulging from an upper surface of theprimary stem portion upward and a protruded portion protruding from thebulging portion to an outside of the primary stem portion as at least apart of the provisional elements in the primary molding step, andmolding the stem portion and the engaging head portion as well asmolding at least one pawl portion protruding on an outer peripheral edgepart of the engaging head portion by compressing an upper end part ofthe provisional element having the bulging portion and the protrudedportion in the secondary molding step, as a most principalconfiguration.

It is preferable that such a manufacturing method of the presentinvention includes, in the primary molding step, molding the primarymolded body by using a die wheel which has an outer side cylindricalbody on which a plurality of penetration holes penetrating from an outerperipheral surface to an inner peripheral surface are drilled and aninner side cylindrical body disposed closely contacting with an innerperipheral surface of the outer side cylindrical body, in which aplurality of concave portions are concaved on the outer peripheralsurface of the inner side cylindrical body, and in which an outerperipheral edge of at least a part of the penetration holes in the innerperipheral surface of the outer side cylindrical body has a partoverlapping with the concave portions of the inner side cylindrical bodyand a part closely contacting with the outer peripheral surface of theinner side cylindrical body.

Further, a manufacturing method of the present invention may include, inthe primary molding step, molding the primary molded body by using abelt mechanism which has an outer side endless belt on which a pluralityof penetration holes penetrating from an outer peripheral surface to aninner peripheral surface are drilled and an inner side endless beltdisposed closely contacting with an inner peripheral surface of theouter side endless belt, in which a plurality of concave portions areconcaved on the outer peripheral surface of the inner side endless belt,and in which an outer peripheral edge of at least a part of thepenetration holes in the inner peripheral surface of the outer sideendless belt has a part overlapping with the concave portion of theinner side endless belt and a part closely contacting with the outerperipheral surface of the inner side endless belt.

Further, it is preferable that the above-mentioned manufacturing methodof the present invention includes molding the bulging portion and theprotruded portion integrally on an upper surface of the primary stemportion so as to be a stick shape, a shape curving as a wave, or apolygon shape.

Next, the molding apparatus provided by the present invention has a diewheel driving rotationally in one direction and an extrusion nozzleextruding a molten synthetic resin material toward the die wheel, andmolds a primary molded body having a flat plate-shaped base portion anda plurality of provisional elements standing on an upper surface of thebase portion to manufacture the molded surface fastener, in which thedie wheel has a concentric bicylindrical structure having an outer sidecylindrical body and an inner side cylindrical body disposed closelycontacting with an inner peripheral surface of the outer sidecylindrical body, a plurality of penetration holes penetrating from anouter peripheral surface to an inner peripheral surface are drilled onthe outer side cylindrical body, a plurality of concave portions towhich the molten synthetic resin material can be flowed are concaved onthe outer peripheral surface of the inner side cylindrical body, and anouter peripheral edge of at least a part of the penetration holes in theinner peripheral surface of the outer side cylindrical body has a partoverlapping with the concave portion of the inner side cylindrical bodyand a part closely contacting with the outer peripheral surface of theinner side cylindrical body, as a most principal configuration.

The other molding apparatus provided by the present invention has a beltmechanism running rotationally in one direction and an extrusion nozzleextruding a molten synthetic resin material toward the belt mechanism,and molds a primary molded body having a flat plate-shaped base portionand a plurality of provisional elements standing on an upper surface ofthe base portion to manufacture the molded surface fastener, in whichthe belt mechanism has a double-belt structure having an outer sideendless belt and an inner side endless belt disposed closely contactingwith an inner peripheral surface of the outer side endless belt androtating the outer side and inner side endless belts synchronically, aplurality of penetration holes penetrating from an outer peripheralsurface to an inner peripheral surface are drilled in the outer sideendless belt, a plurality of concave portions to which the moltensynthetic resin material can be flowed are concaved on the outerperipheral surface of the inner side endless belt, and an outerperipheral edge of at least a part of the penetration holes in the innerperipheral surface of the outer side endless belt has a part overlappingwith the concave portion of the inner side endless belt and a partclosely contacting with the outer peripheral surface of the inner sideendless belt, as a most principal configuration.

Further, in the above two molding apparatuses according to the presentinvention, it is preferable that the concave portion is a concave grooveportion which has a linear shape or a shape curving as a wave. In thiscase, it is particularly preferable that a groove width of each concavegroove portion is set to be 0.005 mm or more and 0.1 mm or less, and agroove depth of each concave groove portion is set to be 0.005 mm ormore and 0.05 mm or less.

The concave portion may be concaved as a polygon shape.

Effects of the Invention

The molded surface fastener according to the present invention has astem portion standing on a base portion and a plurality of male engagingelements having an engaging head portion bulging from an upper end ofthe stem portion toward an outside. In at least a part of the engagingelements (preferably all engaging elements), at least one pawl portionhaving a pawl width dimension narrower than a width dimension of aboundary in the engaging element is protruded on an outer peripheraledge part of each engaging head portion, and a back surface of pawl ofthe pawl portion is formed at different angles with respect to a backsurface of head portion of the engaging head portion.

Here, the pawl width dimension means a dimension of the pawl portion ina direction orthogonal to a protruding direction of the pawl portion ora bulging direction of the engaging head portion and also orthogonal toan upper and lower direction (erecting direction of the stem portion) ofthe molded surface fastener. A width dimension of a boundary means adimension of the boundary in arbitral one direction among directions (ora flat plane) orthogonal to the upper and lower direction (erectingdirection of the stem portion) of the molded surface fastener.Particularly in the present invention, it means a dimension in a machinedirection in a molding step of the molded surface fastener (MD: aflowing direction of the molded surface fastener) among directionsorthogonal to the erecting direction of the stem portion. In theengaging element of the present invention, for example, in a case that ashape of a cross section at the boundary appears a circular shape in aplan view, the width dimension of the boundary is the same size as adiameter of the circular cross section at the boundary.

Each engaging element has a micro pawl portion as mentioned above,thereby, for example in a case that loops (engaging elements) of afemale surface fastener is engaged with male engaging elements of themolded surface fastener according to the present invention, loops of thefemale surface fastener is easy to hook over the pawl portion and theloops of the female surface fastener can be hard to disengage from theengaging element of the present invention.

That is, in a state that the engaging element of the present inventionis got into the loops of the female surface fastener and the moldedsurface fastener of the present invention and the female surfacefastener are engaged, and for example in a case that the loops of thefemale surface fastener are to be disengaged from the engaging elementof the present invention, the loops of the female surface fastenernormally move as if sliding along the outer peripheral edge part of theengaging head portion in the engaging element of the present invention.

In this case, in the present invention, since a micro pawl portionhaving the above-mentioned back surface of pawl is protruded on theouter peripheral edge part of the engaging head portion, the loops ofthe female surface fastener is easy to hook over the outer peripheraledge part of the engaging head portion and becomes hard to disengagefrom the engaging element of the present invention.

Thus, in the present invention, an engaging strength (peeling strength)with respect to the female surface fastener of the molded surfacefastener can be effectively enhanced by the micro pawl portion providedon the outer peripheral edge part of the engaging head portion.Therefore, in a case that the molded surface fastener of the presentinvention is used for goods, for example, such as a disposable diaper,even when various movements are done in a state that the molded surfacefastener and the female surface fastener are engaged, the engaged statecan be stably maintained.

Further, in the present invention, since the pawl portion enhancing theengaging strength is provided on the outer peripheral edge part of theengaging head portion with a micro size having the above-mentioned pawlwidth dimension, effects of the pawl portion on the tactile of themolded surface fastener can be limited. Therefore, by forming theengaging head portion of the engaging element to be, for example, a discshape with a flat upper surface, smooth tactile or soft and flexibletactile can be easily obtained, which enables to provide a male moldedsurface fastener having a substantial engaging strength and comfortabletexture of a top surface stably.

Particularly in the present invention, by forming the pawl portion so asto slope or curve downward toward the base portion, the loops of thefemale surface fastener can easily hook over the outer peripheral edgepart of the engaging head portion. Thereby, the engaging strength(peeling strength) of the molded surface fastener can be moreeffectively enhanced.

In such a molded surface fastener in the present invention, by providinga plurality of pawl portions on one engaging head portion (engagingelement), the engaging strength of the molded surface fastener can bemore enhanced. Particularly in this case, a plurality of pawl portionsare disposed on the engaging head portion regularly, or protruded fromthe engaging head portion with the same angle and the same size eachother, thereby the engaging strength can be stably enhanced.

It should be noted that, in the present invention, a plurality of pawlportions may be disposed on the engaging head portion irregularly. Byarranging a plurality of pawl portions randomly, for example, even in acase that the loops of the female surface fastener are formed randomly,the engaging strength of the molded surface fastener with respect to thefemale surface fastener can be effectively enhanced.

Further, in the molded surface fastener of the present invention, aplurality of pawl portions may be protruded from the engaging headportion at different angles, and also may be formed with differentsizes. Also in these cases, the engaging strength of the molded surfacefastener can be effectively enhanced.

In the molded surface fastener of the present invention, the uppersurface of pawl and the back surface of pawl of the pawl portion areformed to be a sloped surface or a curved surface declining toward a tipend of the pawl. Thereby, the engaging strength of the molded surfacefastener can be more enhanced and the texture of the molded surfacefastener can be further improved.

Moreover, the engaging head portion of the engaging element has a shapeappearing a configuration similar to a cross section at the boundary ofthe engaging element in a plan view. By such an engaging element, theengaging element can be easily and stably molded and the above-mentionedpawl portion can be stably provided on the engaging head portion.

Further, the engaging head portion of the engaging element has a shapeappearing a circle in a plan view, thereby the texture of the moldedsurface fastener can be stably improved.

Particularly in the present invention, a base end part of the pawlportion has a pawl width dimension narrower than one third size,preferably one fifth size, more preferably one seventh size of a widthdimension at the boundary of the engaging element. By having the pawlportion with such a size, the engaging strength of the molded surfacefastener can be stably enhanced and a comfortable texture of the moldedsurface fastener can be stably obtained.

Further, a height dimension from an upper surface of the base portion inthe engaging element is set to be 0.05 mm or more and 1.5 mm or less, awidth dimension at the boundary of the engaging element is set to be 0.1mm or more and 0.5 mm or less, a bulging length (bulging dimension) fromthe boundary part in the engaging head portion is set to be 0.01 mm ormore and 0.2 mm or less and a pawl width dimension in the base end partof the pawl portion is set to be 0.01 mm or more and 0.1 mm or less. Bythe male molded surface fastener in which the engaging elements havingsuch a size are formed, the engaging strength of the molded surfacefastener can be effectively enhanced and a comfortable texture of themolded surface fastener can be stably obtained.

Next, a manufacturing method of the present invention for manufacturingthe above-mentioned molded surface fastener includes a primary moldingstep for molding a primary molded body having a base portion and aplurality of provisional elements standing on the base portion and asecondary molding step for molding a molded surface fastener by heatingthe obtained provisional elements of the primary molded body andcompressing the provisional elements from an upper side.

Particularly, in the primary molding step of the present invention,regarding at least a part of provisional elements (preferably allprovisional elements), a primary stem portion erected from the baseportion, a bulging portion bulging from an upper surface of the primarystem portion upward and a protruded portion protruding from the bulgingportion to an outside of the primary stem portion are molded, and in thesecondary molding step, a stem portion and an engaging head portion ofthe engaging element as well as at least one pawl portion protruding onthe outer peripheral edge part of the engaging head portion are moldedby compressing an upper end part of the provisional element in which thebulging portion and the protruded portion are formed. Thereby, themolded surface fastener of the present invention as described above canbe efficiently and stably manufactured.

In such a manufacturing method of the present invention, in the primarymolding step, a die wheel which has an outer side cylindrical body inwhich a plurality of penetration holes penetrating from an outerperipheral surface to an inner peripheral surface are drilled and aninner side cylindrical body disposed closely contacting with an innerperipheral surface of the outer side cylindrical body, in which aplurality of concave portions are concaved on the outer peripheralsurface of the inner side cylindrical body, and in which an outerperipheral edge of at least a part of the penetration holes (preferablyall penetration holes) in the inner peripheral surface of the outer sidecylindrical body has a part overlapping with the concave portion of theinner side cylindrical body and a part closely contacting with the outerperipheral surface of the inner side cylindrical body is used. Thereby,the primary molded body having a plurality of provisional elements canbe efficiently and stably formed and a molding apparatus of the primarymolded body can be formed in a simple structure.

Further, in the manufacturing method of the present invention, in theprimary molding step, a belt mechanism which has an outer side endlessbelt in which a plurality of penetration holes penetrating from an outerperipheral surface to an inner peripheral surface are drilled and aninner side endless belt disposed closely contacting with an innerperipheral surface of the outer side endless belt, in which a pluralityof concave portions are concaved on the outer peripheral surface of theinner side endless belt, and in which an outer peripheral edge of atleast a part of the penetration holes (preferably all penetration holes)in the inner peripheral surface of the outer side endless belt has apart overlapping with the concave portion of the inner side endless beltand a part closely contacting with the outer peripheral surface of theinner side endless belt may be used. Also in this case, the primarymolded body having a plurality of provisional elements can beefficiently and stably formed and deformation can be hard to remain inthe primary molded body.

Further, in the manufacturing method of the present invention, thebulging portion and the protruded portion of each provisional elementare molded integrally on an upper surface of the primary stem portion soas to be a stick shape, a shape curving as a wave, or a polygon shape,thereby the protruded portion can be easily and stably formed.Thereafter, the secondary molding step is conducted on the obtainedprimary molded body, thereby the engaging element having a micro pawlportion, which is a characteristics of the present invention, can bestably molded.

Next, the molding apparatus of the present invention has a die wheeldriving rotationally in one direction and an extrusion nozzle extrudinga molten synthetic resin material toward the die wheel. The die wheelhas a concentric bicylindrical structure having an outer sidecylindrical body and an inner side cylindrical body disposed closelycontacting with an inner peripheral surface of the outer sidecylindrical body. Further, a plurality of penetration holes penetratingfrom an outer peripheral surface to an inner peripheral surface aredrilled on the outer side cylindrical body, and a plurality of concaveportions to which the molten synthetic resin material can be flowed areconcaved on the outer peripheral surface of the inner side cylindricalbody. Particularly in the present invention, an outer peripheral edge ofat least a part of the penetration holes in the inner peripheral surfaceof the outer side cylindrical body has a part overlapping with theconcave portion of the inner side cylindrical body and a part closelycontacting with the outer peripheral surface of the inner sidecylindrical body.

Such a molding apparatus of the present invention can be formed in asimple structure, and can mold the primary molded body in which aplurality of provisional elements are standing on an upper surface ofthe flat plate-shaped base portion stably and efficiently. Particularly,by the above molding apparatus, small burrs occurred in the primarymolded body can be effectively prevented, and even in a case that theprovisional element is small, the provisional element having at leastone protruded portion bulging from the primary stem portion to anoutside can be stably molded.

The other molding apparatus in the present invention has a beltmechanism running rotationally in one direction and an extrusion nozzleextruding a molten synthetic resin material toward the belt mechanism.The belt mechanism has a double-belt structure having an outer sideendless belt and an inner side endless belt disposed closely contactingwith an inner peripheral surface of the outer side endless belt androtating the outside and inner side endless belts synchronically.Further, a plurality of penetration holes penetrating from an outerperipheral surface to an inner peripheral surface are drilled on theouter side endless belt, a plurality of concave portions to which themolten synthetic resin material can be flowed are concaved on the outerperipheral surface of the inner side endless belt. Particularly in thepresent invention, an outer peripheral edge of at least a part of thepenetration holes in the inner peripheral surface of the outer sideendless belt has a part overlapping with the concave portion of theinner side endless belt and a part closely contacting with the outerperipheral surface of the inner side endless belt.

Also by such a molding apparatus of the present invention, the primarymolded body in which a plurality of provisional elements are standing onthe upper surface of the flat plate-shaped base portion can be stablyand efficiently molded and deformation can be hard to remain in theprimary molded body. Particularly, by the above molding apparatus, smallburrs occurred in the primary molded body can be effectively preventedand even in a case that the provisional element is small, theprovisional element having at least one protruded portion bulging fromthe primary stem portion to an outside can be stably molded.

In the above two molding apparatuses according to the present invention,a concave groove portion which has a linear shape or a shape curving asa wave is formed on the outer peripheral surface of the inner sidecylindrical body or the inner side endless belt as the concave portion.Particularly in this case, a groove width of each concave groove portionis set to be 0.005 mm or more and 0.1 mm or less, and a groove depth ofeach concave groove portion is set to be 0.005 mm or more and 0.05 mm orless. Due to the above, the protruded portion can be stably provided oneach provisional element of the primary molded body and the primarymolded body by which the above-mentioned molded surface fastener of thepresent invention can be obtained can be efficiently molded.

In the present invention, a polygon-shaped concave portion may beconcaved on the outer peripheral surface of the inner side cylindricalbody or the inner side endless belt. Also due to this, the protrudedportion can be stably provided in each provisional element of theprimary molded body and the primary molded body in which theabove-mentioned molded surface fastener of the present invention can beobtained can be efficiently molded.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating a molded surface fasteneraccording to Embodiment 1 of the invention.

FIG. 2 is a perspective view illustrating an engaging element of themolded surface fastener.

FIG. 3 is a plan view illustrating only the engaging element.

FIG. 4 is a front view viewing only the engaging element from a frontand rear direction (machine direction: MD) of the molded surfacefastener.

FIG. 5 is a perspective view viewing only the engaging element updiagonally from a base portion side.

FIG. 6 is a cross-sectional view in VI-VI line shown in FIG. 3.

FIG. 7 is a cross-sectional view in VII-VII line shown in FIG. 3.

FIG. 8 is an enlarged perspective view illustrating a pawl portiondisposed in the engaging element enlarged.

FIG. 9 is a front view viewing the pawl portion from a front and reardirection (MD) of the molded surface fastener enlarged.

FIG. 10 is a schematic view illustrating a manufacturing apparatus ofthe molded surface fastener schematically.

FIG. 11 is a perspective view illustrating an outer side cylindricalbody and an inner side cylindrical body of a molding apparatusschematically.

FIG. 12 is a main part schematic view illustrating a positionrelationship between penetration holes formed on an outer sidecylindrical body and concave groove portions provided on an inner sidecylindrical body.

FIG. 13 is a cross-sectional view illustrating a cross section of theouter side cylindrical body and the inner side cylindrical body.

FIG. 14 is a perspective view illustrating a primary molded bodyobtained by a molding apparatus.

FIG. 15 is a perspective view illustrating a provisional element of theprimary molded body.

FIG. 16 is a plan view illustrating only the provisional element.

FIG. 17 is a front view viewing only the provisional element from afront and rear direction (MD) of the primary molded body.

FIG. 18 is a cross-sectional view in XVIII-XVIII line shown in FIG. 16.

FIG. 19 is a perspective view illustrating an engaging element of amolded surface fastener according to Embodiment 2 of the invention.

FIG. 20 is a plan view illustrating only the engaging element.

FIG. 21 is a front view viewing only the engaging element from a frontand rear direction (MD) of the molded surface fastener.

FIG. 22 is a cross-sectional view in XXII-XXII line shown in FIG. 20.

FIG. 23 is a main part schematic view illustrating a positionrelationship between penetration holes formed on an outer sidecylindrical body and concave groove portions provided on an inner sidecylindrical body.

FIG. 24 is a perspective view illustrating a provisional element of aprimary molded body according to Embodiment 2 of the invention.

FIG. 25 is a plan view illustrating only the provisional element.

FIG. 26 is a front view viewing only the provisional element from afront and rear direction (MD) of the primary molded body.

FIG. 27 is a perspective view illustrating an engaging element of amolded surface fastener according to Embodiment 3 of the invention.

FIG. 28 is a plan view illustrating only the engaging element.

FIG. 29 is a front view viewing only the engaging element from a frontand rear direction (MD) of the molded surface fastener.

FIG. 30 is a cross-sectional view in XXX-XXX line shown in FIG. 28.

FIG. 31 is a main part schematic view illustrating a positionrelationship between penetration holes formed on an outer sidecylindrical body and concave groove portions provided on an inner sidecylindrical body.

FIG. 32 is a perspective view illustrating a provisional element of theprimary molded body according to Embodiment 3 of the invention.

FIG. 33 is a plan view illustrating only the provisional element.

FIG. 34 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 1.

FIG. 35 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 2.

FIG. 36 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 3.

FIG. 37 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 4.

FIG. 38 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 5.

FIG. 39 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 6.

FIG. 40 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 7.

FIG. 41 is a main part schematic view illustrating a positionrelationship between penetration holes of an outer side cylindrical bodyand concave groove portions of an inner side cylindrical body accordingto modification example 8.

FIG. 42 is a schematic view illustrating a manufacturing apparatus of amolded surface fastener according to a first modification exampleschematically.

FIG. 43 is a schematic view illustrating a manufacturing apparatus of amolded surface fastener according to a second modification exampleschematically.

FIG. 44 is a plan view illustrating a conventional engaging element.

FIG. 45 is a side view illustrating a surface fastener having theengaging element.

FIG. 46 is a plan view illustrating another conventional engagingelement.

FIG. 47 is a side view illustrating a surface fastener having theengaging element.

DESCRIPTION OF EMBODIMENT

Hereinafter, preferred embodiments of the present invention aredescribed in detail with Embodiments referring to drawings. It should benoted that the present invention is not limited thereto, and variouschanges can be made as long as they have a substantially same structureand same functional effects. For example, in the Embodiments below, anumber, a disposing position and a forming density of male engagingelement disposed on a base portion of a molded surface fastener is notlimited in particular, and can be changed arbitrarily.

Embodiment 1

FIG. 1 is a perspective view illustrating a molded surface fasteneraccording to Embodiment 1 of the invention. FIGS. 2-5 are views viewingan engaging element of the molded surface fastener from variousdirections. FIGS. 6 and 7 are cross-sectional views of the engagingelement. FIGS. 8 and 9 are enlarged views illustrating a pawl portiondisposed in the engaging element enlarged.

It should be noted that, in the following explanation, a front and reardirection regarding a molded surface fastener and a primary molded bodymeans a length direction of a molded surface fastener and a primarymolded body molded long as described later, and also means a directionalong a machine direction (M direction or MD) in which a molded surfacefastener or a primary molded body flow in a manufacturing step of themolded surface fastener.

A left and right direction means a width direction orthogonal to alength direction and along an upper surface (or a lower surface) of thebase portion of the molded surface fastener. In this case, the left andright direction and the width direction can be also referred to as acrossing direction (C direction or CD) orthogonal to the machinedirection (MD). An upper and lower direction (thickness direction) meansa height direction orthogonal to the length direction and orthogonal toan upper surface (or lower surface) of the base portion of the moldedsurface fastener.

The molded surface fastener 1 of Embodiment 1 shown in FIG. 1 ismanufactured by molding a thermoplastic resin using a manufacturingapparatus 40 having a molding apparatus 50 and a heat press apparatus70, as described later. The molded surface fastener 1 is formed assheet-shaped which is long in a machine direction of the manufacturingapparatus 40 and has a rectangular shape in a plan view. It should benoted that a length dimension and a width dimension of the moldedsurface fastener 1 of the present invention are not limited inparticular, and it can be arbitrarily changed by cutting the moldedsurface fastener 1. The molded surface fastener 1 may have a shape otherthan a rectangular shape in a plan view.

Further, a kind of synthetic resin forming the molded surface fastener 1is not also limited in particular. However, for example, suchthermoplastic resins as polypropylene, polyester, nylon, polybutyleneterephthalate, or a copolymer of these can be adopted as a material ofthe molded surface fastener 1. In Embodiment 1, the molded surfacefastener 1 is formed of polypropylene.

The molded surface fastener 1 of Embodiment 1 has a thin plate-shapedbase portion 2 and a plurality of engaging elements 10 erected from anupper surface of the base portion 2 vertically. The base portion 2 isformed by having a predetermined thickness, and the upper surface and alower surface of the base portion 2 are formed flat and parallel to eachother.

A plurality of engaging elements 10 are disposed in line along a machinedirection (MD) and a crossing direction (CD). It should be noted that,in the present invention, an arranging position of the engaging elements10 are not limited, as described above. For example, a plurality ofengaging elements 10 may be in line on the base portion 2 with azigzag-shaped arranging pattern or with the other pattern, and also maybe provided on the base portion 2 randomly.

Each engaging element 10 in Embodiment 1 has a stem portion 11 standingon the base portion 2, a disc- or dish-shaped engaging head portion 12formed by bulging from a whole periphery of an upper end of the stemportion 11 toward an outside and two micro pawl portions 14 protruded onan outer peripheral edge part of the engaging head portion 12,respectively.

The stem portion 11 of the engaging element 10 is standing vertically onthe base portion 2, and has a frustum of cone shape in which a crosssectional area orthogonal to the upper and lower direction graduallyincreases as it is close to the base portion 2. In particular, a lowerend part of the stem portion 11 in Embodiment 1 is formed curving so asto enlarge the outer peripheral surface downward. It should be notedthat, in the present invention, a shape of the stem portion 11 is notlimited to a frustum of cone shape, and for example, it may be atruncated pyramid shape such as a truncated square pyramid, a columnarshape, or a prism shape such as a quadrangular prism.

The engaging head portion 12 of the engaging element 10 has a disc shapeand formed integrally on the stem portion 11 via a boundary 16.Particularly, the engaging head portion 12 in Embodiment 1 has a shapeappearing a circle in a plan view viewing the engaging element 10 fromthe upper side. The circular shape of the engaging head portion 12 in aplan view is similar with a circular shape of a cross section orthogonalto the upper and lower direction at the boundary 16 of the engagingelement 10.

It should be noted that, the similarity referred in the specificationincludes not only a case of congruence that when enlarging or reducing asize of a scale of one shape so as to correspond to a scale of the othershape and overlapping both shapes, they totally correspond, but also acase of overlapping with an area of 85% or more, preferably with an areaof 90% or more.

Particularly in this case, the engaging head portion 12 is formed so asto have a diameter of more than 1.0 times and 3.0 times or less,preferably 1.3 times or more and 2.0 times or less with respect to adiameter D of the circular cross section at the boundary 16 of theengaging element 10 in a plan view of the engaging element 10. It shouldbe noted that, in a case that the engaging head portion appears apolygon in a plan view, the engaging head portion is formed so as alength of one corresponding side to be more than 1.0 times and 3.0 timesor less, preferably 1.3 times or more and 2.0 times or less with respectto an arbitral side of the polygonal cross section at the boundary ofthe engaging element.

The engaging head portion 12 of Embodiment 1 has a flat top end surfaceof head portion 13 a disposed parallel to the upper surface of the baseportion 2. Further, a donut-shaped back surface of head portion 13 bextending flatly from the boundary 16 with the stem portion 11 toward anoutside is disposed on an opposite side of the top end surface of headportion 13 a so as to oppose to the base portion 2. Moreover, a curvedsurface-shaped outer peripheral side surface 13 c is disposed from theouter periphery of the top end surface of head portion 13 a to the backsurface of head portion 13 b.

It should be noted that, in the present invention, a shape of theengaging head portion 12 may have a shape other than a circlecorresponding to a shape of the cross section of the stem portion 11 ina plan view. The engaging head portion 12 does not need to bulge fromthe whole periphery of the upper end of the stem portion 11. Further, ina plan view of the molded surface fastener 1, a central position of theengaging head portion 12 in one engaging element 10 and a centralposition in a cross section (cross section of the boundary 16) of theupper end of the stem portion 11 may be displaced each other.

Each engaging element 10 of Embodiment 1 has two pawl portions 14protruding from the outer peripheral side surface 13 c of the engaginghead portion 12 toward an outside. Two pawl portions 14 of each engagingelement 10 protrudes from the outer peripheral side surface 13 c of theengaging head portion 12 in a direction extending radially about acenter of the engaging head portion 12 along a radial direction of theengaging head portion 12 appearing a circular shape in a plan view so asto be arranged regularly with respect to one engaging head portion 12.Particularly, in a case of Embodiment 1, in all the engaging elements10, two pawl portions 14 protrudes in an opposing direction each otherfrom the outer peripheral side surface 13 c of the engaging head portion12 along the left and right direction (C direction) so as to be in apoint-symmetrical position relationship each other in a plan view of theengaging element 10.

Each pawl portion 14 has a shape hanging downward toward a tip end as aclaw of birds, as showing the enlarged views in FIGS. 8 and 9. Each pawlportion 14 has an upper surface of pawl 15 a declining toward the tipend, a back surface (lower surface) of pawl 15 b disposed opposing tothe base portion 2 and a pair of side wall surfaces 15 c disposedbetween the upper surface of pawl 15 a and the back surface of pawl 15b.

In this case, at a base end part linking to the engaging head portion 12of the pawl portion 14, a pawl width dimension F (see FIG. 8) between apair of side wall surfaces 15 c of the pawl portion 14 is set to be onethird or less of a dimension (width dimension) of M direction (MD) atthe boundary 16 of the engaging element 10, preferably one fifth orless, further preferably one seventh or less. Each pawl portion 14 isformed having such a pawl width dimension F, thereby the pawl portion 14contributing to an improvement of the engaging strength of the moldedsurface fastener 1 can be provided at the outer peripheral edge part ofthe engaging head portion 12 stably and an effect which the pawl portion14 gives on the tactile of the molded surface fastener 1 can be limited,as described later.

It should be noted that, in a case of Embodiment 1, since the shape ofthe boundary 16 of the engaging element 10 in a plan view is a circle,the dimension of M direction at the boundary 16 becomes equal to thedimension in diameter D at the boundary 16. Also in a case that theshape of the boundary 16 of the engaging element 10 in a plan view is apolygon such as a square, for example, it is preferable that the pawlwidth dimension F between a pair of side wall surfaces 15 c of the pawlportion 14 is set to be one third or less of a dimension in M directionat the boundary 16 of the engaging element 10, preferably one fourth orless.

Further, in the pawl portion 14 in Embodiment 1, a pawl width dimensionF between a pair of side wall surfaces 15 c decreases from the base endpart of the pawl portion 14 toward a pawl tip end, and a pawl heightdimension between the upper surface of pawl 15 a and the back surface ofpawl 15 b has a shape decreasing from the base end part of the pawlportion 14 toward the pawl tip end.

Particularly in Embodiment 1, the upper surface of pawl 15 a of the pawlportion 14 is formed as a curved surface declining toward the tip end.The back surface of pawl 15 b of the pawl portion 14 is formed, as shownin FIG. 9, facing to a lower direction than the back surface of headportion 13 b of the engaging head portion 12 and also formed as a curvedsurface curving as a concaved shape. That is, an inclination angle (forexample, an angle sloping with respect to a horizontal surface parallelto the upper surface of the base portion) is different between the backsurface of pawl 15 b of the pawl portion 14 and the back surface of headportion 13 b of the engaging head portion 12.

The pawl portion 14 is formed as above, thereby the engaging strength ofthe molded surface fastener 1 can be effectively enhanced and acomfortable texture of the upper surface of the molded surface fastener1 can be stably obtained. It should be noted that, in the presentinvention, the upper surface of pawl 15 a and the back surface of pawl15 b of the pawl portion 14 may be formed not as a curved surface, butas a flat surface.

In Embodiment 1, specific sizes of each engaging element 10 are set tobe as follows.

For example, a height dimension A of the engaging element 10 from theupper surface of the base portion 2 in the upper and lower direction isset to be 0.05 mm or more and 1.5 mm or less, preferably 0.2 mm or moreand 1.0 mm or less. A diameter B of the engaging head portion 12 in aplan view of the engaging head portion 12 is set to be 0.2 mm or moreand 0.6 mm or less. It should be noted that, in a case that the engaginghead portion appears a polygon shape in a plan view, for example, adimension of the engaging head portion in M direction in a plan view ofthe engaging head portion is set to be 0.2 mm or more and 0.6 mm orless.

A height dimension C of the engaging head portion 12 in the engagingelement 10 (that is, a height dimension from the boundary 16 of theengaging element 10 to the upper end of the engaging head portion 12) isset to be 0.01 mm or more and 0.1 mm or less. A diameter D at theboundary 16 of the engaging element 10 is set to be 0.1 mm or more and0.5 mm or less. In a case that the boundary appears as a polygon shapein a plan view, the dimension of the boundary in M direction is set tobe 0.1 mm or more and 0.5 mm or less.

A bulging dimension (bulging length) from a position of the boundary 16of the engaging element 10 to a most outer edge position of the engaginghead portion 12 in the engaging head portion 12 is set to be 0.01 mm ormore and 0.2 mm or less, preferably 0.02 mm or more and 0.1 mm or less.A bulging angle θ1 formed by the outer peripheral side surface 13 c ofthe stem portion 11 and the back surface of head portion 13 b of theengaging head portion 12 in the engaging element 10 is set to be 90° ormore and 140° or less.

A pawl width dimension F between a pair of side wall surfaces 15 c atthe base end part of the pawl portion 14 is set to be 0.01 mm or moreand 0.10 mm or less, preferably 0.03 mm or more and 0.08 mm or less. Apawl length dimension G from a boundary position between the backsurface of head portion 13 b of the engaging head portion 12 and theback surface of pawl 15 b of the pawl portion 14 to the tip end positionof the pawl portion 14 is set to be 0.01 mm or more and 0.04 mm or less.A pawl protruding angle θ2 which becomes an inclination angle of animaginary line connecting an intermediate position between the upper andlower surfaces at the base end part of the pawl portion 14 and a tip endof the pawl with respect to a horizontal surface parallel to the uppersurface of the base portion 2 is set to be more than 0° and 90° or less.

The molded surface fastener 1 of Embodiment 1 having the above structureis manufactured by using a manufacturing apparatus 40 as shown in FIG.10.

The manufacturing apparatus 40 has a molding apparatus 50 conducting aprimary molding step and a heat press apparatus 70 heating and pressingthe primary molded body 5 molded in the primary molding step.

The molding apparatus 50 of Embodiment 1 has a die wheel 51 whichrotates drivingly in one direction (in a counterclockwise direction inFigures), an extrusion nozzle 55 which is disposed opposing to acircumferential surface of the die wheel 51 and extruding a moltensynthetic resin material continuously and a pickup roller 56 which isdisposed at a downstream side in a rotating direction of the die wheel51 compared to the extrusion nozzle 55.

The die wheel 51 has a cylinder-shaped outer side cylindrical body(outer side sleeve) 52 and a cylinder-shaped inner side cylindrical body(inner side sleeve) 53 disposed closely contacting to an inside of theouter side cylindrical body 52, which become a mold, and a rotationaldriving roller 54 rotating the outer side and inner side cylindricalbodies 52, 53 in one direction. In this case, the die wheel 51 has abicylindrical structure in which the outer side cylindrical body 52 andthe inner side cylindrical body 53 are disposed rotatably andconcentrically. A cooling jacket not shown in Figures distributing aliquid coolant is provided inside the rotational driving roller 54 andcan cool the primary molded body 5 molded on the peripheral surface ofthe die wheel 51 efficiently.

As shown in FIGS. 11-13, a plurality of penetration holes 57 penetratingfrom the outer peripheral surface to the inner peripheral surface of theouter side cylindrical body 52 are provided on the outer sidecylindrical body 52 of the die wheel 51 as cavities molding a primarystem portion 21 of the primary molded body 5 as mentioned later. Theplurality of penetration holes 57 are formed corresponding to anarrangement of the engaging elements 10 of the molded surface fastener 1to be manufactured. In a case of Embodiment 1, the plurality ofpenetration holes 57 are formed in a circumferential direction which isto be an M direction (MD) of the outer side cylindrical body 52 at apredetermined pitch and also formed in a C direction (CD) parallel to acenter axis of the outer side cylindrical body 52 at a predeterminedpitch.

Such an outer side cylindrical body 52 of Embodiment 1 is formed bymanufacturing a cylinder-shaped primary outer side cylindrical body, andthen drilling a plurality of penetration holes 57 on the primary outerside cylindrical body at a predetermined position. In this case, theprimary outer side cylindrical body is manufactured of metals such asnickel or stainless steel which are conventionally known. It ispreferable that the outer side cylindrical body 52 is formed seamless,that is, which has no joint, and can be manufactured by electrocastingor rolling, for example. Further, Known techniques can be used as aprocessing method of a plurality of penetration holes 57. For example,laser, electron beam, machining, etching or drilling method can be used.It should be noted that, in the present invention, a molding method forthe outer side cylindrical body 52, a size of the outer side cylindricalbody 52, and a shape and an arrangement of the penetration hole 57 arenot limited in particular.

A plurality of concave groove portions 61 are formed on the outerperipheral surface of the inner side cylindrical body 53 ofEmbodiment 1. The inner side cylindrical body 53 and the concave grooveportion 61 can be manufactured also by using the same method as in thecase of manufacturing the outer side cylindrical body 52 and thepenetration hole 57. Each concave groove portion 61 is concaved linearlyalong the C direction (CD) parallel to the center axis of the cylinderof the inner side cylindrical body 53, and has a size with which asynthetic resin forming the molded surface fastener 1 can flow into in amolten state. Particularly, in a case of Embodiment 1, the concavegroove portion 61 of the inner side cylindrical body 53 is formed in thecircumferential direction which is to be an M direction at apredetermined pitch so as to overlap with a diameter of the penetrationhole 57 formed on the outer side cylindrical body 52, and crosses with acircular outer peripheral edge of the penetration hole 57 of the outerside cylindrical body 52.

In Embodiment 1, a forming pitch of the penetration hole 57 provided onthe outer side cylindrical body 52 in a circumferential direction and aforming pitch of the concave groove portion 61 provided on the innerside cylindrical body 53 in a circumferential direction are set bycorresponding each other so as the positions to overlap as above.However, in the present invention, a forming pitch of the penetrationhole 57 on the outer side cylindrical body 52 and a forming pitch of theconcave groove portion 61 on the inner side cylindrical body 53 do notneed to correspond each other. For example, the concave groove portion61 of the inner side cylindrical body 53 is provided with a formingpitch smaller than the one corresponding to the penetration hole 57 ofthe outer side cylindrical body, thereby two or more pawl portions 14can be formed stably on the engaging head portion 12 of each engagingelement 10. On the other hand, the concave groove portion 61 of theinner side cylindrical body 53 is provided with a forming pitch largerthan the one corresponding to the penetration hole 57 of the outer sidecylindrical body 52, thereby the molded surface fastener having both theengaging element 10 in which the pawl portion 14 is protruded on theengaging head portion 12 and the engaging element in which the pawlportion 14 is not protruded on the engaging head portion can beobtained.

Each concave groove portion 61 of the inner side cylindrical body 53 inEmbodiment 1 has a groove bottom surface and a pair of groove side wallsurfaces disposed opposing and parallel to each other so as a crosssection to be a square. In this case, a groove width of each concavegroove portion 61 is set to be 0.01 mm or more and 0.10 mm or less,preferably 0.03 mm or more and 0.08 mm or less. A groove depth of eachconcave groove portion 61 is set to be 0.005 mm or more and 0.05 mm orless, preferably 0.005 or more and 0.03 mm or less, further preferably0.01 mm or more and 0.025 mm or less.

The groove width of the concave groove portion 61 is set to be 0.01 mmor more and the groove depth is set to be 0.005 mm or more, thereby, inmolding the primary molded body 5, the molten synthetic resin can flowfrom the penetration holes 57 of the outer side cylindrical body 52 intoeach concave groove portion 61 of the inner side cylindrical body 53smoothly, and the solidified primary molded body 5 can be demolded fromthe concave groove portion 61 stably. Further, the groove width of theconcave groove portion 61 is set to be 0.10 mm or less and the groovedepth is set to be 0.05 mm or less, thereby the above-mentioned micropawl portion 14 can be stably formed on each engaging element 10 of themolded surface fastener 1. The concave groove portion 61 formed on theinner side cylindrical body 53 may be formed so as to have anapproximately U-shaped cross section.

In Embodiment 1, when viewing a position relationship between thepenetration hole 57 provided on the outer side cylindrical body 52 andthe concave groove portion 61 provided on the inner side cylindricalbody 53, a circular-shaped outer peripheral edge of each penetrationhole 57 disposed on the inner peripheral surface of the outer sidecylindrical body 52 has two groove overlapped parts 58 a overlappingwith the concave groove portion 61 of the inner side cylindrical body 53and two arc-shaped close contacting parts 58 b disposed between twooverlapped parts and directly contacting to the outer peripheral surfaceof the inner side cylindrical body 53, as shown in FIGS. 12 and 13.

The outer peripheral edge of all the penetration holes 57 has the grooveoverlapped part 58 a and the close contacting part 58 b respectively,thereby, when molding the primary molded body 5, a plurality ofprovisional elements 20 having a primary stem portion 21, a bulgingportion 22 and a protruded portion 25 as shown in FIGS. 15-18 can bestably formed on the base portion 2, as mentioned later. Particularly,in this case, the groove width of the concave groove portion 61 is setto be one third, preferably one fifth and further preferably one seventhor less of a dimension in M direction of the penetration hole 57 (in acase of Embodiment 1, a dimension of a diameter of the penetration hole)in the inner peripheral surface of the outer side cylindrical body 52.

The heat press apparatus 70 in the manufacturing apparatus 40 ofEmbodiment 1 has a pair of upper and lower pressing rollers (calenderrollers) 71, 72 disposed on the downstream side of the pickup roller 56,and the upper side pressing roller 71 and the lower side pressing roller72 are disposed opposing to each other at a predetermined interval. Inthis case, the interval between the upper side and the lower sidepressing rollers 71, 72 can be adjusted by a height adjustment means notshown in Figures, and is adjusted corresponding to a height dimensionfrom a lower surface (back surface) of the base portion 2 to the top endsurface of head portion 13 a of the engaging head portion 12 in theengaging element 10 of the molded surface fastener 1 to be manufactured.

The upper side pressing roller 71 has a heat source inside not shown inFigures, and a temperature of a surface of the upper side pressingroller 71 is set to be a temperature at which the synthetic resinforming the molded surface fastener 1 can be softened, specifically, apredetermined temperature of −40° C. or more of a melting point of thesynthetic resin forming the primary molded body 5 and −10° C. or less ofthe melting point. The upper side pressing roller 71 is disposed so asto rotate in a counterclockwise direction in FIG. 10, and the outerperipheral surface of the upper side pressing roller 71 becomes a partpressing the heated provisional element 20 of the primary molded body 5molded in the primary molding step from an upper side.

The lower side pressing roller 72 is disposed so as to rotate in aclockwise direction in FIG. 10, and becomes a supporting surfacesupporting the primary molded body 5 to be conveyed from a lower side.In the present invention, instead of the upper side pressing roller 71and/or the lower side pressing roller 72, an upper side belt mechanismand/or a lower side belt mechanism not shown in Figures can be used. Inthis case, the upper side and lower side belt mechanisms have an endlessbelt and a pair of left and right rotating rollers which the endlessbelt is wound around and which rotates the endless belt in onedirection.

In a case of manufacturing the molded surface fastener 1 using themanufacturing apparatus 40 having the molding apparatus 50 and the heatpress apparatus 70 as above, firstly, a primary molding step for moldingthe primary molded body 5 by the molding apparatus 50 is conducted. Inthe primary molding step, the molten synthetic resin material isextruded continuously from the extrusion nozzle 55 toward the peripheralsurface of the die wheel 51.

At this time, since the die wheel 51 is rotating drivingly in onedirection, the base portion 2 of the molded surface fastener 1 is moldedcontinuously between the extrusion nozzle 55 and the die wheel 51 byextruding the synthetic resin material to the peripheral surface. Inthis case, an interval between the extrusion nozzle 55 and the die wheel51 is adjusted so as to correspond to a thickness dimension of the baseportion 2 of the molded surface fastener 1 to be manufactured.

At the same time of molding the base portion 2, a plurality ofprovisional elements 20 as shown in FIGS. 15-18 are integrally molded onthe base portion 2 by the above-mentioned outer side and inner sidecylindrical bodies 52, 53 of the die wheel 51, thereby the primarymolded body 5 is manufactured.

Here, the primary molded body 5 (also referred to as a preliminarymolded body) molded by the molding apparatus 50 of Embodiment 1 has athin plate-shaped base portion 2 and a plurality of provisional elements20 standing on an upper surface of the base portion 2, as shown in FIGS.15-18. The base portion 2 of the primary molded body 5 becomes the baseportion 2 of the molded surface fastener 1 as it is.

The provisional element 20 formed on the primary molded body 5 is a partwhich becomes an engaging element 10 of the molded surface fastener 1 bybeing pressed and molded in a secondary molding step. In this case, eachprovisional element 20 has a frustum of cone-shaped primary stem portion21 standing on the base portion 2, a stick-shaped bulging portion 22bulging partially from an upper surface of the primary stem portion 21upward, and two protruded portions (provisional pawl portions) 25 formedintegrally and continuously to the bulging portion 22 and protruding soas to bulge to an outside of the primary stem portion 21.

The primary stem portion 21 is molded by the synthetic resin beingfilled into the penetration holes 57 provided on the outer sidecylindrical body 52, and has a frustum of cone shape such that a crosssection orthogonal to the upper and lower direction gradually increasesas close to the base portion 2.

The primary stem portion 21 becomes a stem portion 11 of the moldedsurface fastener 1 by pressing the provisional element 20 from the upperside in the secondary molding step and deforming an upper end part ofthe primary stem portion 21. Therefore, a lower end part of the primarystem portion 21 has the same shape as the lower end part of the stemportion 11. The primary stem portion 21 can be formed to be a truncatedpyramid shape such as a truncated square pyramid, a columnar shape, or aprism shape such as a quadrangular prism corresponding to the shape ofthe stem portion 11 of the molded surface fastener 1 to be manufactured.

The bulging portion 22 and the protruded portion (provisional pawlportion) 25 are molded such that the synthetic resin flows from thepenetration holes 57 of the outer side cylindrical body 52 into theconcave groove portions 61 provided on the inner side cylindrical body53 and enters along the concave groove portions 61 and into a partbeyond the penetration holes 57 in the primary molding step. In thiscase, the bulging portion 22 is formed on the upper surface of theprimary stem portion 21 along the C direction (CD), and two protrudedportions 25 are formed protruding from both end parts of the bulgingportion 22 in the C direction orthogonal to an erecting direction of theprimary stem portion 21 beyond the primary stem portion 21.

The bulging portion 22 and the protruded portion 25 are molded by theconcave groove portion 61 whose cross section provided on the inner sidecylindrical body 53 is square-shaped. However, due to a shrinking incooling and solidifying the bulging portion 22 and the protruded portion25, they have a stick shape whose cross section appears an approximatelyU-shape with roundness.

The molding of the protruded portion 25 is conducted not by filling thesynthetic resin into all concave portions 61 of the inner sidecylindrical body 53, but the protruded portion 25 is formed such thatthe synthetic resin flowing from the penetration holes 57 of the outerside cylindrical body 52 into the concave groove portions 61 enters intoa part of the concave groove portions 61 along the concave grooveportion 61 so as to overflow a forming region of the penetration hole 57a little (for example, a distance of about 0.01 mm or more and 0.04 orless from a region of the penetration hole 57). The protruded portion 25molded in the primary molding step is a part which becomes the pawlportion 14 of the molded surface fastener 1 by pressing the provisionalelement 20 from the upper side in the secondary molding step.

The primary molded body 5 molded in the primary molding step can beobtained such that the molten synthetic resin extruded from theextrusion nozzle 55 is solidified by being held on the outer peripheralsurface of the die wheel 51, cooled and half rotated. Thereafter, theprimary molded body 5 is peeled off continuously from the outerperipheral surface of the die wheel 51 by the pickup roller 56. At thistime, the protruded portion 25 of the primary molded body 5 is pulledout smoothly from the concave groove portion 61 of the inner sidecylindrical body 53 and the penetration hole 57 of the outer sidecylindrical body 52 while elastic deforming.

The primary molded body 5 peeled off from the die wheel 51 is conveyedtoward the heat press apparatus 70 which conducts the secondary moldingstep, and introduced between the upper side pressing roller 71 and thelower side pressing roller 72 of the heat press apparatus 70.

In the secondary molding step, when the primary molded body 5 passesbetween the upper side and the lower side pressing rollers 71, 72, atleast upper end part of each provisional element 20 of the primarymolded body 5 is softened by heating of the upper side pressing roller71, while the base portion 2 of the primary molded body 5 is held by thelower side pressing roller 72 from the lower side, each provisionalelement 20 of the primary molded body 5 is pressed by the upper sidepressing roller 71 from the upper side thereby the upper end part of theprovisional element 20 is compressed. At this time, a temperature of theperipheral surface of the roller in the upper side pressing roller 71 isset to be a predetermined temperature of −40° C. or more of a meltingpoint of the synthetic resin of the primary molded body and −10° C. orless of the melting point, as described above.

Due to the above, the engaging head portion 12 having the top endsurface of head portion 13 a which was made flat by the outer peripheralsurface of the upper side pressing roller 71 after the upper end part ofthe primary stem portion 21, the bulging portion 22 and the protrudedportion 25 in the provisional element 20 are thermal deformed is molded,and the pawl portion 14 protruding from the outer peripheral sidesurface 13 c of the engaging head portion 12 is molded by the protrudedportion 25. Thus, the molded surface fastener 1 of Embodiment 1 shown inFIG. 1 is manufactured.

Thereafter, the manufactured molded surface fastener 1 which is long ina machine direction is conveyed to a cutting part not shown in Figures,then cut in a predetermined length at the cutting part and collected, oris wound as a roll shape by a collecting roller in a state of longmolded surface fastener 1 and collected.

In the molded surface fastener 1 of Embodiment 1 manufactured as above,two micro pawl portions 14 protruding along the C direction are providedon the engaging head portion 12 of each engaging element 10respectively. Particularly, each pawl portion 14 in Embodiment 1 has aconcave surface-shaped back surface of pawl 15 b curving to a lower sidethan the back surface of head portion 13 b of the engaging head portion12. Therefore, when the molded surface fastener 1 of Embodiment 1 isengaged with a loop which becomes an engaging element 10 of a femalesurface fastener, the loop of the female surface fastener easily hookwith the pawl portion 14 of each engaging element 10 and the loop ishard to slip off from each engaging element 10.

Accordingly, the molded surface fastener 1 of Embodiment 1 has a moresubstantial engaging strength (peeling strength) than conventional andordinary molded surface fasteners not having the pawl portion 14, and anengaging state with respect to the female surface fastener can be stablymaintained.

Moreover, in the molded surface fastener 1 of Embodiment 1, the top endsurface of head portion 13 a and the outer peripheral side surface ofhead portion 13 c of the engaging head portion 12 of each engagingelement 10 are formed as smooth and continuous surface. In addition, thepawl portion 14 provided so as to enhance the engaging strength isformed to be smaller than the engaging head portion 12, and the uppersurface of the pawl portion 14 is formed as a curved surface decliningtoward the pawl tip end.

Therefore, an effect which the pawl portion 14 gives on tactile of themolded surface fastener 1 can be limited. As a result, the moldedsurface fastener 1 of Embodiment 1 can have a comfortable texture suchas smooth tactile or soft and flexible tactile can be obtained when themolded surface fastener 1 is touched from the upper surface side inwhich the engaging elements 10 are standing.

The molded surface fastener 1 of Embodiment 1 which has a substantialengaging strength and a comfortable texture as above is preferably usedfor goods to be put on and taken off from the body, for example, such asa disposable diaper, a diaper cover for babies, a supporter protectingjoints of arms and legs, a corset for waist and gloves.

Embodiment 2

FIGS. 19-21 are views viewing an engaging element provided in the moldedsurface fastener of Embodiment 2 from various directions, and FIG. 22 isa cross-sectional view of the engaging element.

It should be noted that, the molded surface fastener 1 a of Embodiment 2is formed so as the number of the pawl portion 14 provided on theengaging head portion 12 of each engaging element 10 a to be four, whichis different from the above mentioned Embodiment 1, but is substantiallythe same as the molded surface fastener 1 explained in theabove-mentioned Embodiment 1 except that the number of disposition ofthe pawl portion 14 is changed.

Accordingly, in Embodiment 2, and Embodiment 3 and each modificationexample described later, different structures from the molded surfacefastener 1 according to the above-mentioned Embodiment 1 are mainlyexplained. The explanation of parts or members having substantially thesame structures as the molded surface fastener 1 according to theabove-mentioned Embodiment 1 is omitted by using the same referencesigns.

The molded surface fastener 1 a of Embodiment 2 has a thin plate-shapedbase portion 2 and a plurality of engaging elements 10 a erectedvertically from an upper surface of the base portion 2, and a pluralityof engaging elements 10 a are disposed lining along the M direction (MD)and the C direction (CD). Each engaging element 10 a has a stem portion11 standing on the base portion 2, a disc-shaped engaging head portion12 formed integrally on the stem portion 11 and four pawl portions 14protruded in the outer peripheral edge part of the engaging head portion12.

In the engaging element 10 a of Embodiment 2, four pawl portions 14 areprotruded from the outer peripheral side surface 13 c of the engaginghead portion 12 and from the engaging head portion 12 in the M directionand the C direction along a radial direction of the engaging headportion 12. The four pawl portions 14 are arranged regularly atpositions of 0°, 90°, 180°, 270° about a center of the engaging headportion 12 appearing a circular shape in a plan view of the engagingelement 10 a shown in FIG. 20.

A shape and a size of respective pawl portions 14 in Embodiment 2 arethe same as each pawl portion 14 provided in the molded surface fastener1 of the above-mentioned Embodiment 1. Each pawl portion 14 has a curvedsurface-shaped upper surface of pawl 15 a declining toward a tip end, aback surface of pawl 15 b curving concavely and disposed opposing to thebase portion 2 and a pair of side wall surfaces 15 c disposed betweenthe upper surface of pawl 15 a and the back surface of pawl 15 b.

The molded surface fastener 1 a of Embodiment 2 having the engagingelements 10 a in which four pawl portions 14 as above are disposed ismanufactured by using the manufacturing apparatus 40 having the moldingapparatus 50 and the heat press apparatus 70 as shown in FIG. 10, as inthe case of the above-mentioned Embodiment 1.

It should be noted that, in a case of Embodiment 2, a cylinder-shapedinner side cylindrical body 53 a forming the die wheel 51 of the moldingapparatus 50 has a different structure from the inner side cylindricalbody 53 used in the above-mentioned Embodiment 1 to provide four pawlportions 14 on each engaging element 10 a.

The inner side cylindrical body (inner side sleeve) 53 a used inEmbodiment 2 has a plurality of concave groove portions 62 formed on theouter peripheral surface. However, on the outer peripheral surface ofthe inner side cylindrical body 53 a, not only linear-shaped concavegroove portions 62 along the C direction as in the above-mentionedEmbodiment 1 but also a plurality of concave groove portions 62 along acircumferential direction of the cylinder which is to be the M directionare concaved.

That is, the concave groove portion 62 of Embodiment 2 has a pluralityof first concave groove portions 62 a along the C direction and aplurality of second concave groove portions 62 b along thecircumferential direction of the cylinder which is to be the Mdirection. In this case, the first concave groove portion 62 a disposedalong the C direction of the inner side cylindrical body 53 a and thesecond concave groove portion 62 b disposed along the M directionoverlap respectively with the diameter of the penetration hole 57 formedon the outer side cylindrical body 52 and are formed at a predeterminedpitch respectively so as the first and the second concave grooveportions 62 a, 62 b to cross orthogonally to each other at a centerposition of each penetration hole 57.

The circular-shaped outer peripheral edge of each penetration hole 57disposed on the inner peripheral surface of the outer side cylindricalbody 52 has four groove overlapped parts 58 a overlapping with the firstand the second concave groove portions 62 a, 62 b of the inner sidecylindrical body 53 a and four arc-shaped close contacting parts 58 bdirectly contacting with the outer peripheral surface of the inner sidecylindrical body 53 a.

In Embodiment 2, by conducting the primary molding step using themolding apparatus 50 having the above-mentioned inner side cylindricalbody 53 a, a primary molded body 5 a having a plurality of provisionalelements 20 a as shown in FIGS. 24-26 on the base portion 2 is molded.In this case, each provisional element 20 a has a frustum of cone-shapedprimary stem portion 21 standing on the base portion 2, a bulgingportion 22 a bulging partially from the upper surface of the primarystem portion 21 upward and crossing as a + figure shape and fourprotruded portions 25 extending so as to bulge from the bulging portion22 a to an outside of the primary stem portion 21.

In this case, the bulging portion 22 a and the protruded portion 25 aremolded such that the synthetic resin flows from the penetration hole 57of the outer side cylindrical body 52 into the first and the secondconcave groove portions 62 a, 62 b provided on the inner sidecylindrical body 53 a in the primary molding step. The bulging portion22 a is formed on the upper surface of the primary stem portion 21 alongthe C direction and the M direction, and four protruded portions 25 areprotruding continuously from each end part of the + figure-shapedbulging portion 22 a in the C direction and the M direction. Therefore,the bulging portion 22 a and the protruded portion 25 in Embodiment 2appears as + figure-shaped in which two stick-shaped bodies areorthogonal to each other in a plan view of the provisional element 20 a.

Thereafter, the primary molded body 5 a having the provisional element20 a shown in FIGS. 24-26 is conveyed to the heat press apparatus 70 bywhich the secondary molding step is conducted, and as in the case of theabove-mentioned Embodiment 1, each provisional element 20 a is heatedand pressed from the upper side. Thus, the molded surface fastener 1 aof Embodiment 2 is manufactured. In this case, four protruded portions25 provided on each provisional element 20 a of the primary molded body5 a becomes four pawl portions 14 disposed on each engaging element 10of the molded surface fastener 1 a by the secondary molding step.

In the molded surface fastener 1 a of Embodiment 2 manufactured asabove, the number of the pawl portion 14 provided on each engagingelement 10 a is four, which is more than in the case of theabove-mentioned Embodiment 1. Therefore, the stronger engaging forcethan the molded surface fastener 1 a of Embodiment 1 can be easilyobtained. In addition, since a size and a shape of each pawl portion 14itself is the same as in the case of the above-mentioned Embodiment 1, atexture of the surface (upper surface) of the molded surface fastener 1a can be comfortable.

Embodiment 3

FIGS. 27-29 are views viewing the engaging element provided in themolded surface fastener of Embodiment 3 from various directions, andFIG. 30 is a cross section of the engaging element.

The molded surface fastener 1 b of Embodiment 3 has a thin plate-shapedbase portion 2 and a plurality of engaging elements 10 b erectedvertically from the upper surface of the base portion 2. Each engagingelement 10 b has a stem portion 11 standing on the base portion 2, adisc-shaped engaging head portion 12 formed integrally on the stemportion 11 and eight pawl portions 14 protruding on the outer peripheraledge part of the engaging head portion 12. A shape and a size of eachpawl portion 14 in Embodiment 3 are the same as each pawl portion 14formed in the molded surface fastener 1 of the above-mentionedEmbodiment 1.

In the engaging element 10 b of Embodiment 3, eight pawl portions 14 areprotruded from the outer peripheral side surface 13 c of the engaginghead portion 12 toward an outside along a radial direction of theengaging head portion 12. The eight pawl portions 14 are arrangedregularly at a predetermined interval so as to have an angle of 45° withrespect to the adjacent pawl portions 14 about a center of the engaginghead portion 12 appearing a circular shape in a plan view of theengaging element 10 b shown in FIG. 28.

The molded surface fastener 1 b of Embodiment 3 having such an engagingelement 10 b is, as in the case of the above-mentioned Embodiment 1,manufactured by using the manufacturing apparatus 40 having the moldingapparatus 50 and the heat press apparatus 70 as shown in FIG. 10.

In a case of Embodiment 3, the cylinder-shaped inner side cylindricalbody (inner side sleeve) 53 b forming the die wheel 51 of the moldingapparatus 50 is different from the inner side cylindrical body 53 usedin the above-mentioned Embodiment 1 to provide eight pawl portions 14 oneach engaging element 10 b. That is, on the outer peripheral surface ofthe inner side cylindrical body 53 b of Embodiment 3, a plurality oflinear-shaped first concave groove portions 63 a disposed along the Cdirection, a plurality of second concave groove portions 63 b disposedalong the circumferential direction of the cylinder which is to be the Mdirection and a plurality of third and fourth concave groove portions 63c, 63 d disposed at an inclination angle of 45° with respect to thefirst and the second concave groove portions 63 a, 63 b are concaved.

In this case, the first concave groove portion 63 a-the fourth concavegroove portion 63 d overlaps with a diameter of the penetration holes 57formed on the outer side cylindrical body 52 and are formed at apredetermined pitch respectively so as to cross each other at a centerposition of each penetration hole 57. The circular-shaped outerperipheral edge of each penetration hole 57 disposed on the innerperipheral surface of the outer side cylindrical body 52 has grooveoverlapped parts 58 a overlapping with the first concave grove portion63 a-the fourth concave groove portion 63 d of the inner sidecylindrical body 53 b and arc-shaped close contacting parts 58 bdirectly contacting with the outer peripheral surface of the inner sidecylindrical body 53 b.

In Embodiment 3, by conducting the primary molding step by using themolding apparatus 50 having the above-mentioned inner side cylindricalbody 53 b, a primary molded body 5 b having a plurality of provisionalelements 20 b as shown in FIGS. 32 and 33 on the base portion 2 isformed. In this case, each provisional element 20 b has a frustum ofcone-shaped primary stem portion standing on the base portion 2, abulging portion 22 b bulging from the upper surface of the primary stemportion 21 upward and crossing as + figure-shaped as well as ×figure-shaped and eight protruded portions 25 extending so as to bulgefrom each end part of the bulging portion 22 b to an outside of theprimary stem portion 21.

In this case, the bulging portion 22 b and the protruded portion 25 aremolded such that the synthetic resin flows from the penetration holes 57of the outer side cylindrical body 52 into the first concave grooveportions 63 a-the fourth concave groove portions 63 d provided on theinner side cylindrical body 53 b in the primary molding step. Thebulging portion 22 b is formed on the upper surface of the primary stemportion 21 along the C direction, the M direction and a directioncrossing with the C and M directions at an inclination angle of 45°, andeight protruded portions 25 are formed protruding from each end part ofthe bulging portion 22 b in a radial direction. Therefore, the bulgingportion 22 b and the protruded portion 25 of Embodiment 3 appear a shapein which four stick-shaped bodies are crossing each other with an angleof 45° and + figure and × figure are combined in a plan view of theprovisional element 20 b.

Thereafter, the primary molded body 5 b having a provisional element 20b shown in FIGS. 32 and 33 are conveyed to the heat press apparatus 70and the secondary molding step is conducted, thereby the molded surfacefastener 1 b of Embodiment 3 is manufactured.

In the molded surface fastener 1 b of Embodiment 3 manufactured asabove, the number of the pawl portion 14 provided on each engagingelement 10 b is eight, which is more than in the case of theabove-mentioned Embodiment 1. Therefore, stronger engaging force can beeasily obtained. Moreover, since a size and a shape of each pawl portion14 itself are the same as in the case of the above-mentioned Embodiment1, a texture of the surface (upper surface) of the molded surfacefastener 1 b can be comfortable.

It should be noted that, in the present invention, the number, a shape,a size and an arrangement of the pawl portion provided on each engagingelement of the molded surface fastener are not limited to theabove-mentioned Embodiment 1-Embodiment 3, and can be changedarbitrarily according to a usage of the molded surface fastener.

For example, in the present invention, in the die wheel 51 of themolding apparatus 5 conducting the primary molding step as describedabove, forming pitches of the concave groove portions 61, 62, 63 a-63 dprovided on the cylinder-shaped inner side cylindrical bodies 53, 53 a,53 b can be arbitrarily changed so as not to correspond intentionally toforming pitches of the penetration hole 57 provided on thecylinder-shaped outer side cylindrical body in a circumferentialdirection or an axis direction.

For example, the forming pitches of the concave groove portions 61, 62,63 a-63 d of the inner side cylindrical bodies 53, 53 a, 53 b are set tobe smaller than the forming pitches of the penetration hole 57 of theouter side cylindrical body 52, thereby the number of the pawl portionprovided on the engaging head portion can be different among eachengaging element. On the other hand, the forming pitches of the concavegroove portions 61, 62, 63 a-63 d of the inner side cylindrical bodies53, 53 a, 53 b can be set to be wider than the forming pitches of thepenetration hole 57 of the outer side cylindrical body 52. Thereby, notonly the number of the pawl portion provided on the engaging headportion can be different among each engaging element, but also themolded surface fastener in which the engaging elements in which the pawlportion is provided on the engaging head portion and the engagingelement in which the pawl portion is not provided on the engaging headportion are standing can be obtained.

In the aforementioned Embodiment 1-Embodiment 3, a plurality of concavegroove portions 61, 62, 63 a-63 d are formed on one inner sidecylindrical body 53, 53 a, 53 b with the same groove width and thegroove depth. However, in the present invention, it is possible that aplurality of concave groove portions 61, 62, 63 a-63 d having differentgroove width or the different groove depth are provided on one innerside cylindrical body 53, 53 a, 53 b. Thereby, a protruding angle and asize of the pawl portion provided on the engaging head portion can bedifferent from each other among each engaging element. Further, forexample, in a case that a plurality of pawl portions are provided withrespect to one engaging head portion, it is also possible that aplurality of pawl portions protruding at different angles or a pluralityof pawl portions having different sizes are provided with respect to theone engaging head portion.

In the present invention, a configuration of the pawl portion can bearbitrarily and easily changed by changing the forming pattern of theconcave groove portion or the concave portion provided on the inner sidecylindrical body of the molding apparatus which conducts the primarymolding step. Here, the forming pattern of the concave groove portion orthe concave portion provided on the inner side cylindrical body isexplained showing some modification examples and using Figures. FIGS.34-41 are main part schematic views explaining schematically a positionrelationship between the concave groove portion or the concave portionprovided on the inner side cylindrical body and the penetration holeprovided on the outer side cylindrical body in each modificationexample.

In these Figures, two circles express the outer peripheral edge of thepenetration hole disposed on the inner peripheral surface of the outerside cylindrical body. A white part expresses the concave groove portionor the concave portion provided on the outer peripheral surface of theinner side cylindrical body, and a gray part expresses a part of theouter peripheral surface of the cylinder on which the concave grooveportion or the concave portion of the inner side cylindrical body is notprovided.

In modification example 1 shown in FIG. 34, a plurality of concavegroove portions 61 disposed linearly along the C direction (CD) areconcaved on the outer peripheral surface of the inner side cylindricalbody (inner side sleeve) 53 c so as to form a stripe pattern. Forexample, in the aforementioned Embodiment 1, only one concave grooveportion 61 disposed on the inner side cylindrical body 53 in the Cdirection is, as shown in FIG. 12, formed at a position along thediameter of the penetration hole 57 with respect to one circularpenetration hole 57 of the outer side cylindrical body 52. However, inthe modification example 1, by making the interval (forming pitch)between each concave groove portion 61 smaller than the above-mentionedEmbodiment 1, a plurality of concave groove portions 61 are arranged soas to cross over one circular penetration hole 57 of the outer sidecylindrical body 52.

In this case, by changing the size of the penetration hole 57 formed onthe outer side cylindrical body 52 or the groove width dimension and theforming interval of the concave groove portion 61 formed on the innerside cylindrical body 53 c appropriately, the number of the concavegroove portion 61 in the C direction formed with respect to one circularpenetration hole 57 can be easily changed.

As the modification example 1, the molded surface fastener ismanufactured by using the inner side cylindrical body 53 c on whichmultiple concave groove portions 61 in the C direction are formed withrespect to one circular penetration hole 57 of the outer sidecylindrical body 52, thereby the molded surface fastener having theengaging element in which three or more pawl portions are protrudedregularly or irregularly on the outer peripheral edge part of theengaging head portion can be easily obtained.

In the above-mentioned Embodiment 1 and the modification example 1, theconcave groove portions 61 in the C direction having a constant groovewidth dimension are provided on the outer peripheral surfaces of theinner side cylindrical bodies 53, 53 c at a constant forming pitch so asthe number to be one or plural with respect to one circular penetrationhole 57 of the outer side cylindrical body 52. However, in the presentinvention, it is also possible that a plurality of concave grooveportions with different groove width dimensions or with differentforming pitches are provided on the outer peripheral surface of theinner side cylindrical bodies 53, 53 c.

Further, in the present invention, it is also possible that the moldedsurface fastener is manufactured not by forming the concave grooveportion in the C direction on the outer peripheral surface of the innerside cylindrical body, but by providing only a plurality of concavegroove portions 64 along the circumferential direction of the cylinderwhich is to be the M direction on the inner side cylindrical body 53 das the modification example 2 is shown in FIG. 35, or by providing onlya plurality of concave groove portions 65 inclining with a predeterminedangle with respect to the C direction or the M direction on the innerside cylindrical body 53 e as the modification example 3 are shown inFIG. 36.

In the above-mentioned Embodiment 2 (FIG. 23) and Embodiment 3 (FIG.31), not only linear-shaped first concave groove portions 62 a, 63 aalong the C direction but also a plurality of second concave grooveportions 62 b, 63 b along the circumferential direction of the cylinderwhich is to be the M direction and the third and fourth concave grooveportions 63 c, 63 d at an inclination angle of 45° in the C direction orthe M direction are also concaved on the outer peripheral surface of theinner side cylindrical bodies 53 a, 53 b with respect to one circularpenetration hole 57 of the outer side cylindrical body 52 one by one.

However, in the present invention, also in the above-mentionedEmbodiment 2 (FIG. 23) and Embodiment 3 (FIG. 31) as well as in themodification example 2 (FIG. 35) and the modification example 3 (FIG.36), the size of the penetration hole 57 formed on the outer cylindricalbody 52 is set to be large or the forming pitch of the concave grooveportions 62, 63 a-63 d, 64, 65 formed on the inner side cylindricalbodies 53 a, 53 b, 53 d, 53 e are set to be small, thereby the arbitralnumber of concave groove portion 62, 63 a-63 d, 64, 65 can be formedrespectively with respect to one circular penetration hole 57 of theouter side cylindrical body 52. Further, a plurality of concave grooveportions with the different groove width dimension or with the differentforming pitch can be also provided. Also by the above means, the moldedsurface fastener having the engaging element in which a plurality ofpawl portions are protruded regularly or irregularly on the outerperipheral edge part of the engaging head portion can be obtained.

Next, in the modification example 4 as shown in FIG. 37, a plurality ofconcave groove portions 66 meandering as a wave along the C directionare concaved on the outer peripheral surface of the inner sidecylindrical body 53 f at a predetermined forming pitch. In themodification example 4, the size of the penetration hole 57 formed onthe outer side cylindrical body 52 or the groove width dimension and theforming pitch of the concave groove portion 66 are changed, thereby oneor a plurality of concave groove portions 66 can be formed with respectto one circular penetration hole 57 of the outer side cylindrical body52.

Moreover, in the modification example 4, a plurality of concave grooveportions 66 meandering as a wave are concaved on the outer peripheralsurface of the inner side cylindrical body 53 f along the C direction.However, in the present invention, a plurality of concave grooveportions 66 meandering as a wave can be also concaved along thecircumferential direction of the cylinder which is to be the M directionor along the direction inclining with a predetermined angle with respectto the C direction or the M direction.

Also by manufacturing the molded surface fastener using the inner sidecylindrical body 53 f on which a plurality of concave groove portions 66meandering as a wave are concaved as in the modification example 4, themolded surface fastener having the engaging element in which a pluralityof pawl portions are protruded regularly or irregularly on the outerperipheral edge part of the engaging head portion can be easilyobtained.

The modification example 5 shown in FIG. 38 is totally in contrast tothe case of the inner side cylindrical body 53 a of the above-mentionedEmbodiment 2 in which the concave groove portion 62 is formed along theC direction and the M direction. A plurality of rectangular-shapedconcave portion (recess) 67 a are formed at a predetermined interval notonly in the C direction but also in the M direction so as the outerperipheral surface of the cylinder of the inner side cylindrical body 53g to remain along the C direction and the M direction.

A plurality of rectangular-shaped concave portion 67 a are concaved onthe outer peripheral surface of the inner side cylindrical body 53 g inthe modification example 5 so as the outer peripheral surface of theinner side cylindrical body 53 g to remain along the C direction and theM direction as a lattice shape. However, in the present invention, aplurality of rectangular-shaped concave portions 67 a can be alsoconcaved so as the lattice shape of the outer peripheral surface of theinner side cylindrical body 53 g to be formed in the direction incliningwith a predetermined angle with respect to the C direction and the Mdirection.

Also by manufacturing the molded surface fastener using the inner sidecylindrical body 53 g of the modification example 5, the molded surfacefastener having the engaging element in which a plurality of pawlportions are protruded regularly or irregularly on the outer peripheraledge part of the engaging head portion can be easily obtained.

In the modification example 6 shown in FIG. 39, a plurality oftriangle-shaped concave portions (recesses) 67 b are concaved so as theouter peripheral surface of the cylinder of the inner side cylindricalbody 53 h to extend linearly in various directions (for example, toremain as a radial-shaped pattern). Also by the modification example 6,the size of the penetration hole 57 formed on the outer side cylindricalbody 52 or the dimension and the forming pitch of the concave portion 67b can be appropriately changed. And also by manufacturing the moldedsurface fastener using the inner side cylindrical body 53 h of themodification example 6, the molded surface fastener having the engagingelement in which a plurality of pawl portions are protruded irregularlyon the outer peripheral edge part of the engaging head portion can beeasily obtained.

In the modification example 7 shown in FIG. 40, the outer peripheralsurface of the cylinder of the inner side cylindrical body 53 i and thesquare-shaped concave portions (recesses) 67 c are concaved so as toform a checkered pattern. Also in the modification example 7, the sizeof the penetration hole 57 formed on the outer cylindrical body 52 orthe dimension and the forming pitch of the concave portion 67 c can beappropriately changed. Further, in the modification example 7, thecheckered pattern formed by the concave portion 67 c is formed along thecircumferential direction of the cylinder which is to be the C directionand the M direction. However, in the present invention, the checkeredpattern formed by the outer peripheral surface of the inner sidecylindrical body 53 i and the concave portion 67 c can be formed alongthe direction inclining with a predetermined angle with respect to the Cdirection and the M direction. Also by manufacturing the molded surfacefastener using the inner side cylindrical body 53 i of the modificationexample 7, the molded surface fastener having the engaging element inwhich a plurality pawl portions are protruded regularly or irregularlyon the outer peripheral edge part of the engaging head portion can beeasily obtained.

In the modification example 8 shown in FIG. 41, a plurality of regularhexagon-shaped concave portions (recesses) 67 d are formed on the outerperipheral surface of the inner side cylindrical body 53 j at apredetermined interval so as the outer peripheral surface of the innerside cylindrical body 53 j to remain as a tortoiseshell-like pattern.Also in the modification example 7, the size of the penetration hole 57formed on the outer side cylindrical body 52 or the size and the formingpitch of the regular hexagon-shaped concave portion 67 d can beappropriately changed, and the regular hexagon-shaped concave portion 67d can be also formed so as to slope with respect to the C direction orthe M direction. Also by manufacturing the molded surface fastener usingthe inner side cylindrical body 53 j of the above modification example8, the molded surface fastener having the engaging element in which aplurality of pawl portions are protruded regularly or irregularly on theouter peripheral edge part of the engaging head portion can be easilyobtained.

Since a plurality of pawl portions are protruded regularly orirregularly on the engaging head portion of each engaging element ineach molded surface fastener manufactured using the inner sidecylindrical bodies 53 c-53 j shown in the above-mentioned modificationexample 1-the modification example 8, the molded surface fasteners havea strong engaging force with respect to the female surface fastenerhaving loops stably and a texture of the surface (upper surface) of themolded surface fastener can be comfortable.

In the above-mentioned Embodiment 1-Embodiment 3 and the modificationexample 1-the modification example 8, the cases that the molded surfacefastener is manufactured using the manufacturing apparatus 40 shown inFIG. 10 are explained. However, in the present invention, it is possiblethat the molded surface fasteners according to the above-mentionedEmbodiment 1-Embodiment 3 and the modification example 1-themodification example 8 are manufactured by using a manufacturingapparatus 40 a according to the first modification example shown in FIG.42 or a manufacturing apparatus 40 b according to the secondmodification example 2 shown in FIG. 43.

For example, the manufacturing apparatus 40 a according to the firstmodification example shown in FIG. 42 has a molding apparatus 80conducting the primary molding step and a heat press apparatus 70 aheating and pressing the primary molded body 5 formed in the primarymolding step.

The molding apparatus 80 according to the first modification example hasa die wheel 51 rotating drivingly in one direction (in a clockwisedirection in Figures), a press roller 82 disposed on an upper side ofthe die wheel 51 at a predetermined interval and rotating drivingly inan opposite direction to the die wheel 51 (in a counterclockwisedirection in Figures), an extrusion nozzle 85 extruding the moltensynthetic resin material continuously between the die wheel 51 and thepress roller 82 and a pickup roller 56 disposed at a downstream side inthe rotating direction of the die wheel 51 compared to the extrusionnozzle 85.

In this case, the die wheel 51 of the first modification example hassubstantially the same structure as the die wheel 51 of Embodiment 1shown in FIG. 10. That is, a plurality of penetration holes 57 as shownin FIGS. 11-13 are drilled on the outer side cylindrical body 52 of thedie wheel 51 corresponding to an arrangement of the engaging element 10of the molded surface fastener 1 to be manufactured so as to penetratefrom the outer peripheral surface to the inner peripheral surface of theouter side cylindrical body 52.

A plurality of concave groove portions 61 are concaved and linearly onthe outer peripheral surface of the inner side cylindrical body 53 alongthe C direction orthogonal to the M direction in which the primarymolded body 5 flows. Further, in this case, an interval between the diewheel 51 and the press roller 82 is adjusted so as to correspond to athickness dimension of the base portion 2 of the molded surface fastener1 to be manufactured.

The heat press apparatus 70 a according to the first modificationexample has a pair of upper and lower pressing rollers 73, 74 disposedat a downstream side of the pickup roller 56, and the upper sidepressing roller 73 and the lower side pressing roller 74 are disposedopposing at a predetermined interval. An interval between the upper sideand the lower side pressing rollers 73, 74 can be adjusted by a heightadjustment means not shown in Figures.

The lower side pressing roller 74 according to the first modificationexample has the same structure as the upper side pressing roller 71 inthe heat press apparatus 70 of Embodiment 1 shown in FIG. 10, and isdisposed so as to rotate in a counterclockwise direction in FIG. 42.Further, the upper side pressing roller 73 according to the firstmodification example has the same structure as the lower side pressingroller 72 in the heat press apparatus 70 of Embodiment 1 shown in FIG.10, and forms a supporting surface supporting the primary molded body 5to be conveyed.

In a case of manufacturing the molded surface fastener 1 using themanufacturing apparatus 40 a of the first modification example shown inFIG. 42, firstly, the primary molding step for molding the primarymolded body 5 by the molding apparatus 80 is conducted. In the primarymolding step, the molten synthetic resin material is extrudedcontinuously from the extrusion nozzle 85 between the die wheel 51 andthe press roller 82, thereby the base portion 2 is formed by a spacebetween the die wheel 51 and the press roller 82, and a plurality ofprovisional elements 20 are molded on the base portion 2 by the outsideand inner side cylindrical bodies 52, 53 of the die wheel 51. Thus, theprimary molded body 5 is manufactured.

The primary molded body 5 molded in the primary molding step issolidified by being held on the outer peripheral surface of the diewheel 51, cooled and half rotated, and thereafter, peeled offcontinuously from the outer peripheral surface of the die wheel 51 bythe pickup roller 56. Thus, the primary molded body 5 having a pluralityof provisional elements 20 on the base portion 2 can be obtained.

Then, the primary molded body 5 peeled off from the die wheel 51 isconveyed toward the heat press apparatus 70 a conducting the secondarymolding step in a state the upper side and the lower side are upsidedown, and introduced between the upper side pressing roller 73 and thelower side pressing roller 74 of the heat press apparatus 70 a. Due tothe above means, each provisional element 20 of the primary molded body5 is heated and pressed by the lower side pressing roller 74 and theupper end part of each provisional element 20 can be compressed. Thus,the molded surface fastener 1 according to Embodiment 1 can be stablymanufactured. In this case, the molded surface fasteners according tothe above-mentioned Embodiment 2 and Embodiment 3, and the modificationexample 1-the modification example 8 can be also easily and stablymanufactured by changing the forming pattern of the concave grooveportion or the concave portion concaved on the outer peripheral surfaceof the inner side cylindrical body 53.

Next, the manufacturing apparatus 40 b according to the secondmodification example shown in FIG. 43 has a molding apparatus 90conducting the primary molding step and a heat press apparatus 70 aheating and pressing the primary molded body 5 molded in the primarymolding step. In this case, the heat press apparatus 70 a according tothe second modification example is formed substantially the same as theheat press apparatus 70 a according to the above-mentioned firstmodification example.

The molding apparatus 90 according to the second modification examplehas a molding side belt mechanism 91 running rotationally in onedirection (in a clockwise direction in Figures), a press side beltmechanism 96 disposed on the upper side of the molding side beltmechanism 91 at a predetermined interval and running rotationally in anopposite direction to the molding side belt mechanism 91 (in acounterclockwise direction in Figures) and an extrusion nozzle 95disposed opposing to the outer peripheral surface of the belt of themolding side belt mechanism 91 and extruding the molten synthetic resinmaterial continuously.

The molding side belt mechanism 91 of the second modification examplehas an outer side endless belt 92 to be a mold, an inner side endlessbelt 93 disposed closely contacting with the inside of the outer sideendless belt 92 and a pair of first rotating rollers 94 which theoutside and the inner side endless belts 92, 93 are wound around andwhich make the outside and the inner side endless belts 92, 93 runrotationally, and can make the outside and the inner side endless belts92, 93 rotate synchronically.

A plurality of penetration holes 57 which are the same as thepenetration holes 57 provided on the outer side cylindrical body 52 (seeFIGS. 11-13) of the above-mentioned Embodiment 1 are drilled on theouter side endless belt 92. Each penetration hole 57 is formed at aposition of the outer side endless belt 92 corresponding to thearrangement of the engaging element 10 of the molded surface fastener tobe manufactured penetrating from the outer peripheral surface to theinner peripheral surface of the outer side endless belt 92.

A plurality of concave groove portions are concaved on the outerperipheral surface of the inner side endless belt 93. Each concavegroove portion is formed linearly along the C direction with a size withwhich the synthetic resin forming the molded surface fastener 1 in amolten state can flow into. In the second modification example, eachconcave groove portion formed on the inner side endless belt 93 has thesame size and cross-sectional shape as in the case of the inner sidecylindrical body 53 (see FIGS. 11-13) of the above-mentioned Embodiment1, and are formed at a position of overlapping with a diameter of thepenetration hole 57 formed on the outer side endless belt 92 in the Mdirection at a predetermined pitch.

Also in the second modification example, when viewing a positionrelationship between the penetration hole 57 provided on the outer sideendless belt 92 and the concave groove portion provided on the innerside endless belt 93, the circular-shaped outer peripheral edge of eachpenetration hole 57 disposed on the inner peripheral surface of theouter side endless belt 92 has a groove overlapped part overlapping withthe concave groove portion of the inner side endless belt 93 and anarc-shaped close contacting part directly contacting with the outerperipheral surface of the inner side endless belt 93.

The press side belt mechanism 96 has an endless belt for pressing 97 anda pair of second rotating rollers 98 which the endless belt for pressing97 are wound around and which make the endless belt for pressing 97 runrotationally.

Further, in this case, an interval between the molding side beltmechanism 91 and the press side belt mechanism 96 (that is, an intervalbetween an outer surface of the outer side endless belt 92 in themolding side belt mechanism 91 and an outer surface of the endless beltfor pressing 97 of the press side belt mechanism 96) is adjusted to be asize corresponding to the thickness dimension of the base portion 2 ofthe molded surface fastener 1 to be manufactured.

In a case of manufacturing the molded surface fastener 1 using such amanufacturing apparatus 40 b of the second modification example shown inFIG. 43, firstly, the primary molding step for molding the primarymolded body 5 by the molding apparatus 90 is conducted. In the primarymolding step, while driving rotationally the molding side belt mechanism91 and the press side belt mechanism 96, the molten synthetic resinmaterial is extruded continuously from an extrusion nozzle 95 to theouter surface of the outer side endless belt 92 of the molding side beltmechanism 91.

Thereby, the base portion 2 is molded between the outer side endlessbelt 92 of the molding side belt mechanism 91 and the endless belt forpressing 97 of the press side belt mechanism 96, and a plurality ofprovisional elements 20 are molded on the base portion 2 by the outsideand the inner side endless belts 92, 93 of the molding side beltmechanism 91. Thus, the primary molded body 5 is manufactured.

The primary molded body 5 molded in the primary molding step issolidified by flowing along the machine direction between the moldingside belt mechanism 91 and the press side belt mechanism 96.Particularly, in the molding apparatus 90 of the second modificationexample, compared to the above-mentioned Embodiment 1 (see FIG. 10) orthe case of the first modification example (see FIG. 42), the primarymolded body 5 can be conveyed linearly when cooling, and the speed ofconveyance and the length of conveyance can be easily adjusted.Therefore, an advantage that the primary molded body 5 can beefficiently molded and the primary molded body 5 to be molded is hard todeform can be obtained.

Then, the cooled and solidified primary molded body 5 is peeled off fromthe molding side belt mechanism 91 such that it is pulled by aconveyance roller not shown in Figures from a space between the moldingside belt mechanism 91 and the press side belt mechanism 96. Thereafter,the primary molded body 5 is conveyed toward the heat press apparatus 70a in a state that the upper direction and the lower direction are upsidedown, and introduced between the upper side pressing roller 73 and thelower side pressing roller 74 of the heat press apparatus 70 a.

Due to the above means, each provisional element 20 of the primarymolded body 5 are heated and pressed by the lower side pressing roller74, and the upper end part of each provisional element 20 can becompressed. Therefore, the molded surface fastener 1 according toEmbodiment 1 can be stably manufactured. Further, in this case, themolded surface fasteners according to the above-mentioned Embodiment 2and Embodiment 3, and the modification example 1-the modificationexample 8 can be easily and stably manufactured by changing the formingpattern of the concave groove portion or the concave portion concaved onthe outer peripheral surface of the inner side endless belt 93.

REFERENCE SIGNS LIST

-   -   1, 1 a, 1 b Molded surface fastener    -   2 Base portion    -   5, 5 a, 5 b Primary molded body    -   10 Engaging element    -   10 a, 10 b Engaging element    -   11 Stem portion    -   12 Engaging head portion    -   13 a Top end surface of head portion    -   13 b Back surface of head portion    -   13 c Outer peripheral side surface    -   14 Pawl portion    -   15 a Upper surface of pawl    -   15 b Back surface of pawl (Lower surface)    -   15 c Side wall surface    -   16 Boundary    -   20 Provisional element    -   20 a, 20 b Provisional element    -   21 Primary stem portion    -   22 Bulging portion    -   22 a, 22 b Bulging portion    -   25 Protruded portion (Provisional pawl portion)    -   40 Manufacturing apparatus    -   40 a, 40 b Manufacturing apparatus    -   50 Molding apparatus    -   51 Die wheel    -   52 Outer side cylindrical body (Outer side sleeve)    -   53 Inner side cylindrical body (Inner side sleeve)    -   53 a-53 j Inner side cylindrical body (Inner side sleeve)    -   54 rotational driving roller    -   55 Extrusion nozzle    -   56 Pickup roller    -   57 Penetration hole    -   58 a Groove overlapped part    -   58 b Close contacting part    -   61 Concave groove portion    -   62 Concave groove portion    -   62 a First concave groove portion    -   62 b Second concave groove portion    -   63 a First concave groove portion    -   63 b Second concave groove portion    -   63 c Third concave groove portion    -   63 d Fourth concave groove portion    -   64, 65, 66 Concave groove portion    -   67 a, 67 b Concave portion (Recess)    -   67 c, 67 d Concave portion (Recess)    -   70, 70 a Heat press apparatus    -   71 Upper side pressing roller (Calender roller)    -   72 Lower side pressing roller (Calender roller)    -   73 Upper side pressing roller    -   74 Lower side pressing roller    -   80 Molding apparatus    -   82 Press roller    -   85 Extrusion nozzle    -   90 Molding apparatus    -   91 Molding side belt mechanism    -   92 Outer side endless belt    -   93 Inner side endless belt    -   94 First rotating roller    -   95 Extrusion nozzle    -   96 Press side belt mechanism    -   97 Endless belt for pressing    -   98 Second rotating roller    -   A Height dimension of engaging element    -   B Diameter of engaging head portion    -   C Height dimension of engaging head portion    -   D Diameter of engaging element at boundary    -   E Bulging dimension of engaging head portion    -   F Pawl width dimension    -   G Pawl length dimension    -   θ1 Bulging angle of engaging head portion    -   θ2 Pawl protruding angle    -   MD Machine direction    -   CD Crossing direction

The invention claimed is:
 1. A manufacturing method of a molded surfacefastener made of synthetic resin in which a plurality of male engagingelements are standing on an upper surface of a flat plate-shaped baseportion and each engaging element has a stem portion standing on thebase portion and an engaging head portion bulging from an upper end ofthe stem portion toward an outside and formed integrally on the stemportion, including: a primary molding step for molding a primary moldedbody having the base portion and a plurality of provisional elementsstanding on the base portion and a secondary molding step for moldingthe molded surface fastener by heating the provisional elements of theprimary molded body and compressing the provisional elements from anupper side, wherein the manufacturing method includes: in the primarymolding step, molding a primary stem portion erected from the baseportion, a bulging portion bulging partially from an upper surface ofthe primary stem portion upward and a protruded portion protruding fromthe bulging portion to an outside of the primary stem portion as atleast a part of the provisional elements, and in the secondary moldingstep, molding the stem portion and the engaging head portion as well asmolding at least one pawl portion protruding on an outer peripheral edgepart of the engaging head portion by compressing an upper end part ofthe provisional element having the bulging portion and the protrudedportion.
 2. The manufacturing method of the molded surface fasteneraccording to claim 1, including: in the primary molding step, moldingthe primary molded body by using a die wheel which has an outer sidecylindrical body on which a plurality of penetration holes penetratingfrom an outer peripheral surface to an inner peripheral surface aredrilled and an inner side cylindrical body disposed closely contactingwith an inner peripheral surface of the outer side cylindrical body, inwhich a plurality of concave portions are concaved on the outerperipheral surface of the inner side cylindrical body, and in which anouter peripheral edge of at least a part of the penetration holes in theinner peripheral surface of the outer side cylindrical body has a partoverlapping with the concave portions of the inner side cylindrical bodyand a part closely contacting with the outer peripheral surface of theinner side cylindrical body.
 3. The manufacturing method of the moldedsurface fastener according to claim 1, including: in the primary moldingstep, molding the primary molded body by using a belt mechanism whichhas an outer side endless belt on which a plurality of penetration holespenetrating from an outer peripheral surface to an inner peripheralsurface are drilled and an inner side endless belt disposed closelycontacting with an inner peripheral surface of the outer side endlessbelt, in which a plurality of concave portions are concaved on the outerperipheral surface of the inner side endless belt, and in which an outerperipheral edge of at least a part of the penetration hole in the innerperipheral surface of the outer side endless belt has a part overlappingwith the concave portions of the inner side endless belt and a partclosely contacting with the outer peripheral surface of the inner sideendless belt.
 4. The manufacturing method of the molded surface fasteneraccording to claim 1, including: molding the bulging portion and theprotruded portion integrally on an upper surface of the primary stemportion so as to be a stick shape, a shape curving as a wave, or apolygon shape.